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:
84,978 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 1 of 2)

problem #24

Nov 182014

Town & Country 6-cyl

  • 176,000 miles


I filled my gas tank full, and drove my car to a parking lot, later on I went to leave the parking slot and smelled gasoline, and found leakage underneath the vehicle. I took it to an independent mechanic who indicated the metal ring that applies mechanical pressure to the fuel pump / sending unit is severely corroded causing the tangs that hold down the assembly tightly in the tank hole, to fail, causing the pressure on the seal to be inadequate and allow the seal to function. This problem is not causing the check engine lamp to be illuminated, thus is not warning me of this dangerous situation. I purchased another 2004 Chrysler Town and country tank, and while it is possibly serviceable, the ring on it is also corroded, and is likely to fail again if put into service. I live in the northern rust belt states. Driving in northeast Ohio, western pa where corrosion is enhanced by salt applied to prevent snow and ice accidents. I have not yet taken the failed tank off the vehicle. I am wondering if Chrysler should repair this for free and recall others that are likely having the same problems in rust prone areas. Was told that this exact tank was only used in 2004. I am currently operating by filling the tank with less than 10 gallons at a time from an empty tank who's is an inconvenient to do things and probably still not safe in case of a roll over accident, so I hope to get a response from you fairly soon, thank you for you attention in this matter!

- Hubbard, OH, USA

problem #23

Jun 032013

Town & Country 6-cyl

  • 80,000 miles
For the past year, after filling up the gas tank, our van would start to shudder and sometimes stall immediately after pulling out of the station. It would restart after a minute, but stall again, especially after a left turn. It happened again two days ago when my wife filled up, and she and my young son were coming home, and turned left at an intersection with a traffic light. The engine started dying and the van shuddered violently and just quit. Fortunately, she was able to coast through the light and pull into a lot on the right. The dash lights were all lit, but the engine was not running. It did restart again, and she brought it home, though the van rode very rough, like the road was bumpy, when it wasn't. I read 30-40 stories from people who had the exact same issue, on various model years. Many of those stories are on this very page, for owners' complaints. But as of now, Chrysler is offering no repair for an obvious design or manufacturing fault. Please, Chrysler, help us with the repair costs for this wide-spread and very dangerous problem, before people die.

- Louisville, KY, USA

problem #22

May 022014

Town & Country 6-cyl

  • 11,100 miles
We have been having issues with the car. The problem started with not being able O fill the tank it the fuel dispenser would shut off as the gas would backup. Then that went away. The new issue started. After a full fill up of the tank, and driving about a mile or so, the vehicle shuts off. On 5/2/2014 it happened again after full fillup. I filled up the tank. Drove about a mile and was at a turn and the car shut off. I lost control of my steering as it locked up due to engine being off. Luckily I was able to stop the car just before it hit the guard rail at the turn. This problem has been going on for about 6 months and this was the closest coming to an accident. It has shut off on the freeway as well when we took long trips. Created a dangerous situation since we loose steering wheel control. The way to get back is to put car in neutral (while it is moving) and turn the car on and then shift it to drive.

- West Chester, OH, USA

problem #21

May 292013

Town & Country 6-cyl

  • 80,375 miles


Van stalls after filling gas tank.

- Lexington, MI, USA

problem #20

Apr 192012

Town & Country 6-cyl

  • 98,000 miles
The internal valve in the fuel tank is stuck open allowing liquid fuel to enter and saturate the evap canister with fuel during a fuel fill up. When the evap system purges the canister, liquid fuel is drawn into the intake manifold causing an over rich air/fuel condition that will cause the engine to stall within 5 minutes of the fuel fill up. If the stall occurs while the vehicle is at low speeds and steering around a corner, the power steering assist fails suddenly. This can make the vehicle uncontrollable during a tight low-speed turn with the potential to cause an accident.

- Livonia, MI, USA

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problem #19

Dec 112011

Town & Country

  • miles
While accelerating to merge onto highway, lost engine power and power steering. This has happened several times after refueling. Nearly caused an accident.

- Crofton, MD, USA

problem #18

Sep 012011

Town & Country 6-cyl

  • Automatic transmission
  • 70,000 miles


The contact owns a 2004 Chrysler Town and country. The contact stated that the vehicle stalled without warning after refueling. The failure occurred several times. The vehicle was taken to a local mechanic who performed a diagnostic test, but was unable to locate a failure code. The vehicle was not repaired. The failure mileage was 70,000 and the current mileage was 80,000. The VIN information was not available. Updated 01/04/12

- Livonia , MI, USA

problem #17

May 262010

Town & Country 6-cyl

  • 45,000 miles
Engine stalls each time the fuel tank is filled. This happens only once per fill up and only after leaving the fuel station and entering the adjacent roadway. This is a dangerous condition as there is no warning and no power to steer and pull off the road to re-start. Re-starting can take a while to achieve in traffic. This is a dangerous defect apparently requiring replacement of the entire fuel tank" why is Chrysler not required to recall these vehicles as it is a very common and dangerous failure"

- Lyons, CO, USA

problem #16

Jun 092007

Town & Country

  • 107,000 miles
The contact owns a 2004 Chrysler Town and country. The contact stated after adding fuel to the vehicle it began to stall. The contact took the vehicle to the dealer regarding the stalling and they were unable to diagnose the failure. The failure always occurred when gasoline was added to the fuel tank. The contact stated that the stalling was a major safety issue with his year make a model vehicle which could potentially cause a crash to occur. The failure mileage was 107,000.

- Williamsburg, VA, USA

problem #15

May 032011

Town & Country

  • 96,000 miles
Engine stalls five minutes after filling up the gas tank with fuel. This happens every time after a fill-up. The stall can occur while driving at any speed. The root cause is due to a failure of a valve in the fuel tank which is designed to pass gasoline vapors to the evap canister when fuel is added to the fuel tank. During a complete fill-up of the fuel tank, liquid gasoline is passing thru the defective valve into the evap canister. When the evap canister is purged, liquid fuel is sucked into the engine manifold, causing an extremely rich fuel/air mixture. The rich mixture causes the engine to stall. The engine is difficult to restart because of the extra fuel present in the manifold.

- Livonia, MI, USA

problem #14

Feb 222011

Town & Country 6-cyl

  • 50,000 miles


My 2004 Chrysler Town & Country minivan stalls everytime after I get gas. I have tried fueling up when my tank is half empty instead of close to empty and nothing seems to make a difference. This is becoming increasingly dangerous as I don't dare drive far after fueling up. One time I was turning the corner and my car died and I could not steer the vehicle and ended up on the wrong side of the road. Thank god no one was on the other side or I would have been in a serious accident and who knows what the extent of the injury would be! I have to make sure I go straight home after getting gas due to the serious of this problem. After I go home and shut the vehicle off and use it the next day it does not stall. I have tried turning the vehicle off after fueling and restarting it and it still stalls. This should not be happening as I only have 60,000 miles on my vehicle and have always maintained it. My dealership is out of business so I can't even address the issue with them. This is extremely upsetting and so aggravating and makes no sense at all. What can I do and who will help me. I am not the only one with this problem, it seems to be widespread. I don't feel I should have to pay for this to be fixed as obviously there is an issue with this model. This has been happening for approximately 6 to 8 months although it could be longer I have lost track it has happened so often. I have really come to dread when I need gas.

- Plainville, MA, USA

problem #13

Dec 012010

Town & Country

  • 126,300 miles
After refilling the tank at any gas station and restarting the vehicle, it runs rough and stalls. The stall can occur anytime from right after the engine restart or up to 5 minutes after restart. The car has stalled in the gas station on numerous occasions since first noticed in Dec 2010 and several times on the road in traffic. A web search indicated that there was an apparent issue with the vehicles fuel tank and "purge" valve. I found dozens & dozens of complaints. This seems to fit into a safety recall category. Please investigate

- East Brunswick, NJ, USA

problem #12

Feb 162011

Town & Country 6-cyl

  • 20,000 miles
Vehicle stalls after filling with gas. I understand this is a fuel, vapor, water separator that sits on top of the gas tank. I started having this problem in early 2006. I've put up with it and not left the gas station until the engine was running properly. Once I nearly had an accident when entering an interstate entrance ramp and the vehicle stalled. This is a dangerous situation and should be corrected with a recall. Sometimes it is hard to remember what needs to be done after gassing up.

- Otsego, MN, USA

problem #11

Jan 162011

Town & Country 6-cyl

  • 78,000 miles
2004 Chrysler Town and country van. After almost every gas fill up, as you pull into traffic, within seconds the vehicle begins to stall, causing it to jerk violently with the engine stopping. Very dangerous in traffic as we were almost in several traffic crashes. Will stall several times in a row. Van will eventually start and will eventually go, usually shaking a few seconds longer. This appears to be a common problem in these vans. Was informed it is related to the vapor/liquid separator valve at the top of the fuel tank. There is not a simple fix except for an expensive replacement of the gas tank. Since this is such a common problem, I feel this is a dangerous defect and should be replaced by a recall. Last incident around January 16, 2911.

- Roanoke, VA, USA

problem #10

Feb 012007

Town & Country 6-cyl

  • 45,000 miles
My 2004 Chrysler Town and country limited 3.8L 2wd vehicle stalls and engine fails after filling up gasoline tank. Several occasions occurred while vehicle was moving almost causing me to have an accident.

- Rahway, NJ, USA

problem #9

Jan 012008

Town & Country

  • miles
2004 Chrysler Town and country...after fueling the vehicle the engine stalls. This happens usually when the fuel tank was nearing empty than after the tank is filled. When the fuel tank is half full and the vehicle is refueled either nothing happens or there is slight stutter in the vehicle.

- Los Alamitos, CA, USA

problem #8

Nov 022010

Town & Country

  • 105,000 miles
2004 Chrysler Town & Country stalls and dies after filling up the gas tank. This happens every time we fill up the van. My wife was driving my 3yr old to preschool today and it died on her several times when pulling out into traffic. This is a very dangerous problem. Evidently it is a common issue, and the repair is replacing the entire fuel tank.

- Benton, AR, USA

problem #7

Aug 222010

Town & Country 6-cyl

  • 482,000 miles
Van stalls after fillups. Lose power and control of van when accelerating onto road. Very dangerous. This is a common problem with these mini vans. Check the internet and you will see. I am not sure what to do.

- Gainesville, GA, USA

problem #6

Jul 302010

Town & Country

  • 72,496 miles
I have a 2004 Chrysler Town and country mini van. For the last 30,000 miles everytime I fill up with gas the engine will either go through some major hesitations or in many cases it will stall within the first few minutes of driving, or if I have to come to a stop shortly after I refueled. The van will restart, (with some effort) and will not stall again until after the next refueling. Spoke to several mechanics concerning this problem and they indicated that the roll-over switch located in the tank may be defective, may have been splashed/flooded with fuel, or the tank was over filled. To repair the problem I was told I needed to replace the fuel tank since the switch itself is not a serviceable item.

- Pennsauken, NJ, USA

problem #5

Feb 252010

Town & Country 6-cyl

  • 120,000 miles
After filling up with gas, the vehicle greatly hesitates and sometimes stalls. This has put us in dangerous situations in traffic. A few minutes after the fill up, and through the tank of gas it runs fine. This has happened several times and is not corrected.

- Lancaster, PA, USA

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