Huge win for car owners! All TSBs to be made public. The Center for Auto Safety just made the NHTSA (US Government) make public the full text of all TSBs from now on. They are the same organization that has petitioned the NHTSA & filed lawsuits to protect car owners over exploding gas tanks & other major safety issues. Whenever you drive in your car, you are safer thanks in part to a lot of work over the years by this small but very effective consumer advocacy group.

Please take a moment & say thank you by donating $5 or whatever you can to the Center for Auto Safety. Notes: Chances are you didn't want to have to buy a used minivan, but chances are you _also_ didn't realize how much stuff you need to travel with kids. When it comes to hauling around piles of diaper bags and coolers full of snacks, you could do worse than the 2004 Town & Country. Especially when you compare it to the 2005.


hardly worth mentioning
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
90,996 miles

About These NHTSA Complaints:

This data is from the NHTSA — the US gov't agency tasked with vehicle safety. Complaints are spread across multiple & redundant categories, & are not organized by problem.

So how do you find out what problems are occurring? For this NHTSA complaint data, the only way is to read through the comments below. Any duplicates or errors? It's not us.

2004 Chrysler Town & Country fuel system problems

fuel system problem

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2004 Chrysler Town & Country Owner Comments (Page 2 of 2)

« Read the previous 20 complaints

problem #8

Aug 252013

Town & Country

  • 137,600 miles


This vehicle stalls after refueling. I google the problem and I found numerous complaints from people with this problem all having Chrysler/Dodge vehicles. This is a huge safety concern as the vehicles tend to randomly stall after refueling. Several mechanics posted the cause as being a defective value on the top of the fuel tank causing the problem. This is one of those posts. Shops are reporting a problem with the gas tank on Dodge Caravan, Grand Caravan, Plymouth Voyager, and Town and country vans. Shortly after refueling, drivers experience engine stalling. The stalling may repeat several times. The problem is the vapor/liquid separator valve located at the top of the fuel tank. The valve is designed to prevent liquid fuel from entering the charcoal canister/emissions system. When the valve fails, liquid gas can enter the line and fill the charcoal canister. After refueling the PCM on the vehicle detects a change in fuel level. Then, when the engine meets certain temperature and driving criteria, the PCM issues a purge command to the charcoal canister to remove the stored gas vapors. It"S at that point that all the liquid gas in the line gets sucked into the charcoal canister. The PCM expects to see gas vapors entering the intake manifold and it is prepared to adjust air/fuel mixtures to compensate. However, it is not prepared to see liquid gas coming into the intake. That"S what causes the engine to stall. Unfortunately, the only fix is to replace the entire gas tank. Chrysler does not sell the vapor/liquid valve as a separate unit. Once the tank is replaced and the charcoal canister purged, the problem goes away.

- Duluth, MN, USA

problem #7

Jan 012013

Town & Country

  • 58,000 miles
The contact owns a 2004 Chrysler Town and country. The contact stated that whenever she would refuel, the vehicle would stall. The vehicle was taken to the dealer for inspection and they stated that the fuel line needed to be replaced. The vehicle was not repaired. The manufacturer was not notified. The failure mileage was 58,000.

- Mason, OH, USA

problem #6

Feb 122010

Town & Country 6-cyl

  • 75 miles
Within a few minutes of filling the fuel tank, the engine will stalls. It can happen at any speed from 0-50 mph. The engine will stall about 80% of the time after fuelling.

- Canton, GA, USA

problem #5

May 082013

Town & Country 6-cyl

  • 71,000 miles


After filling my 2004 T&C mini van with gas, I pulled out onto the street and drove less than 2 blocks when turning a corner I lost all power when the engine died suddenly and could not steer very well and was almost hit by oncoming traffic. Had to stop put in park and able to start and drive away.

- La Salle, IL, USA

problem #4

Aug 282012

Town & Country

  • 69,889 miles
About 3 min after filling up vehicle stalled after pulling out of station. Power steering failed and could not move out of lane. Took a couple of tries to restart and move to safety. Second time this problem has happened. This will cause an accident!!!

- Essex Junction , VT, USA

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problem #3

Jul 012010

Town & Country

  • 76,000 miles
For the last couple of years, every time we fill the gas tank on our 2004 Town & Country it stalls after driving begins. On multiple occasions it has stalled in front of several lanes of oncoming traffic. The engine totally dies and all power steering is lost. After restarting it runs fine. We have had multiple occasions where collisions have been barely avoided and this is my wife and children in that van. It has been reported on multiple online automotive forums as a common problem. The Chrysler mechanic immediately new the problem when I described the symptoms. He said it is caused by a faulty sensor in the fuel tank and they see it very frequently but unfortunately Chrysler does not acknowledge the problem. This is a serious safety issue and I hope Chrysler decides to do the right thing and it does not take a loss of life to get their attention. I assure you that it is only a matter of time before this becomes reality.

- Newnan, GA, USA

problem #2

Jun 072007

Town & Country 6-cyl

  • 30,000 miles
For the last 5 years every time we fill the gas tank on our 2004 Town & Country with gas is stalls after driving between 50 and 150 yards. On multiple occasions it has stalled in front of several lanes of oncoming traffic after pulling out of gas stations. It has also stalled in front of fast moving oncoming traffic when turning left across oncoming lanes. When it stalls, the motor quits and all power in steering and braking is lost. The van must be put into park in order to restart, which means coming to a complete stop in front of traffic. After restarting it runs fine. We have had approximately 9 occasions where high speed collisions have been very barely avoided, usually with children in the car. It has been reported on automotive online forums and from mechanics as a common problem resulting from a faulty sensor in the Chrysler fuel tanks. Unfortunately Chrysler does not acknowledge this fact.

- Salem, OR, USA

problem #1

Jul 042011

Town & Country 6-cyl

  • 110,000 miles
Every time this vehicle is filled up with gasoline, (87, 89 or higher octane it doesn't matter), it starts to stall & bucks as the engine rpms fluctuate wildly from 600 to 3000 plus. This happens every time that it is filled up to full & has been going on for more than 1 year. Now the check engine light is on. If I only fill it up to 3/4S or even just less than full, the stalling pattern does not occur. I have learned to expect it & either fill it up just shy of full or I drive the van like a standard, (one foot on the brake & the other on the gas). However, I feel that this is only a cheap band-aid for a significant safety issue that warrants a full recall. This issue has been reported multiple times & it would be a shame if it took a serious accident for NHTSA or Chrysler to act on the problem. Especially if it happens to be my wife or my two teenage age children that are involved in any accident. Please act now!

- Jefferson, MA, USA

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