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.


hardly worth mentioning
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
69,986 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.

2005 Dodge Grand Caravan fuel system problems

fuel system problem

Find something helpful? Spread the word.
Get notified about new defects, investigations, recalls & lawsuits for the 2005 Dodge Grand Caravan:

Unsubscribe any time. We don't sell/share your email.

2005 Dodge Grand Caravan Owner Comments

problem #15

Jun 152015

Grand Caravan 6-cyl

  • Automatic transmission
  • 132,000 miles


On two separate occasions within the past month, the engine on my 2005 Dodge Grand Caravan stopped running while I was driving. On both occasions, it was within a mile after filling the gas tank. On one occasion, it occurred while I was making a left turn across oncoming traffic; I was lucky to be able to coast out of the intersection without being broad-sided. Since the engine stopped running, all power assist also stopped, so the car was very difficult to control. I have since read online that this is a relatively common occurrence with Dodge Caravan, particularly with older cars. After filling up the gas tank, the engine may suddenly stop running within a short distance of the gas station. Apparently it has something to do with the gas tank venting, and the only remedy is to replace the gas tank. This is an extremely dangerous situation; it is just a matter of time before someone gets killed. There should be an alert and a recall to correct this problem. Updated 9/25/15

- Alexandria, VA, USA

problem #14

Dec 052013

Grand Caravan 6-cyl

  • 105,000 miles
Every time after refueling the car with a full tank, after about a mile of driving the engine will stumble or die altogether. This causes loss of power steering and power brakes.

- Mahwah, NJ, USA

problem #13

Dec 122014

Grand Caravan 6-cyl

  • 133,689 miles
Roughly 4 blocks after refueling an almost empty tank, the engine in my 2005 Dodge Grand Caravan stalled at approximately 25 mph, right before a 90 degree right turn. Because the engine is quite at nearly idle, I did not notice the engine stopped until I started into the turn. With the engine stalled there was no power steering or power brakes. If I was not a relatively strong person, I would not have been able to steer the car around the corner and to the side of the road in a safe fashion. I doubt that any other member of my family would have successfully negotiated the corner since it almost felt like the steering wheel was locked and the result would have been a significant accident at the very least with the on coming traffic. I was not sure if I might have done something to cause the stall and it did not reoccur, that is until the next fill up today. Fortunately it was not as big a deal today as I was driving at a higher speed (40 mph) at a different location and all that happened was brief loss of power and stumbling over a distance of about 1/4 mile and then resolved itself, which caused no threat to safety like last time. However it proved that there was a problem that consistent with 2 refuels in a row. After searching the internet for these symptoms, it would seem that lots of people are having this problem with 2004 and newer Chrysler minivans and other models, due to a defective valve in the evaporative emission system in the top of the gas tank that can only be fixed by replacing the entire tank at a cost of about $600.

- Camas, WA, USA

problem #12

Apr 012013

Grand Caravan 6-cyl

  • 75,000 miles


The contact owns a 2005 Dodge Grand Caravan. The contact stated that after refueling and driving at 25 mph, the vehicle stalled without warning. The contact mentioned that the vehicle stalled after refueling. The vehicle was able to restart. The vehicle was taken to the dealer where the failure was not able to be duplicated. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was 75,000. Updated 10/8/14 10/24/14 updated 02/03/15

- Chino Hills, CA, USA

problem #11

Aug 212014

Grand Caravan 6-cyl

  • 44,165 miles
Traveling East on the nys I90 yesterday, 12:45pm - lunch rush hour time, approximate speed 62 mph when suddenly the vehicle stopped accelerating. Pumping the gas pedal, holding it down to the floor made no difference, although the rpms were racing. Luckily we were traveling in the far right lane (of the three available) and as I was coasting was able to do so on the shoulder. We were also fortunate that we were near an exit and we able to coast along to this point before we finally had to shut off the car, midway along an exit ramp, along the shoulder. Had we been in one of the other lanes during this mishap I probably would not be in any condition to file a report. Vehicle was placed on a flat bed, driven to our mechanic, where it currently is. I have noticed several complaints regarding the autolocks on this vehicle. Ours were fixed (partially) once. The driver's side rear still does not function as it should and needs to be locked and unlocked manually. This vehicle had no prior owners, purchased new.

- North Tonawanda, NY, USA

problem #10

Feb 012006

Grand Caravan 6-cyl

  • 45,000 miles
I originally called Dodge when this issue started and they would not do anything about it but when we would put the van in reverse the engine would not go into reverse and if you were not listening for it to "catch" you would put on the gas and be going forward. After calling a few times we just gave up and began a habit of shifting into reverse and making sure the vehicle was indeed in reverse. After several years of this we started having a problem with the vehicle speed. The engine would rev but the vehicle would not go if it was under any kind of strain, uphill or grade. After replacing everything from fuel injector to catalytic converter to spark plugs, wires and sensors and spending close to $1000 on it we ended up in a transmission repair shop which found our problem to be a cracked flex plate. That was $1500 more but the problem was fixed. The reverse is now working properly as well so I feel that this flex plate may have been the reverse issue as well.

- Natural Bridge, VA, USA

problem #9

Jan 012014

Grand Caravan 6-cyl

  • 70,000 miles


The fuel pump on our 2005 Dodge Grand Caravan had to be replaced due to cracks and leaks which left a strong fuel odor along with the loss of gasoline. The fuel pump should have lasted at least 100,000 miles but it did not. When I searched online, I found that quite a few owners of the same vehicle had this problem. The sub par parts are costly to replace, especially when considering it was no fault of the owners.

- Nipomo, CA, USA

problem #8

Dec 052006

Grand Caravan 6-cyl

  • 21,000 miles
The first problem was the automatic door locks failed to function when reaching the required speed. Even would not lock with the key took it to mechanic was advised that would have to replace the computer, but by disconnecting the battery that it would reset the computer, it is only a temporary solution.second problem was the door motor stop working had that replaced. Third problem was the front axle broke with no apparent wear, had that replaced. Now it's the gas tank, car wants to stall was advised by mechanic that the gas tank would have to be replaced, that it is a defective valve that has since been corrected in the newer models.

- Baltimore, MD, USA

problem #7

Jun 012012

Grand Caravan 6-cyl

  • 70,000 miles
For at least a year now (dates and mileage above are some sort of approximation) our car has been having trouble upon refueling. As I drive away from the fueling station, within about the first mile the car hesitates, chokes and either threatens to stall or actually stalls. After a few moments, or upon restarting, the car does fine. I have asked the dealer about this and they expressed no knowledge of Chrysler notices about it or what might be causing it. They said it would be expensive to pull the gas tank, so I have left it for now. But having the car do this is dangerous. I googled the problem and found that there are numerous people with this 4th generation Caravan that have the exact same problem. Dodge's mediator suggested that it's a problem with topping off the tank, but I have found that not topping it makes no difference, and as you can see from the online strings I am attaching, there are others who never top off their tank and have the same problem as we do. This is apparently a design flaw that creates a danger. It is expensive for the consumer to fix, and my impression is that it will steadily get worse. We were part of the headlight problem with these cars too. The headlights on the car were unstable from the time we bought the car. After years of complaining, our dealer finally seemed to have fixed the problem, but we had to pay part of it. Since then we have received a notice that Chrysler is taking responsibility for the problem. I hope this gas tank problem will not take so many years to correct as the headlight problem.

- Danbury, CT, USA

problem #6

Aug 142013

Grand Caravan 6-cyl

  • 158,275 miles
The contact owns a 2005 Dodge Grand Caravan. The contact stated that while parked, he noticed a strong gasoline fuel smell. The vehicle was taken to an independent mechanic for diagnosis. The technician stated that the fuel pump housing was fractured and leaking fuel onto the exhaust system. The fuel pump was replaced. The manufacturer was not made aware of the failure. The vehicle was repaired. The approximate failure mileage was 158,275.

- Hillsboro, IL, USA

problem #5

May 012010

Grand Caravan

  • 70,000 miles


Engine stalls after driving a few blocks after refueling creating a dangerous situation.

- Milwaukee, WI, USA

problem #4

Nov 242009

Grand Caravan

  • 80,000 miles
Filling van up with gas. About a mile after leaving the station car stalls. It now occurs each time we fill up with gas. If we need to get onto the interstate we drive around for about a mile for the car to stall and die before we try to get onto the interstate. Apparently this is becoming a problem with the Dodge Grand Caravan. Dealership said this is happening more and more. Dealership said we have to replace the entire gas tank. Approximate cost is $800. We are handling the stalling until we can afford the $800 to fix a design problem. The fuel filter is in the gas tank and since we never have to replace the fuel filter Dodge thought that would be the best place for it. Brilliant design.

- Lebanon, OH, USA

problem #3

Jan 152007

Grand Caravan

  • Automatic transmission
  • 27,750 miles
I am concerned with overall quality control on this vehicle. I purchased this vehicle new to provide safety and comfort for my growing family. I was disappointed in the vehicles performance and gas mileage during the first several weeks of ownership. I returned the vehicle to the dealership and they replaced the oxygen sensor units that they said where defective. Several months later the heater/air conditioning blower went out. Next with less than 20,000 miles on the vehicle I had to replace the brakes. Now with less than 28.000 miles on the vehicle I noticed that the passenger side floor was soaked, the vehicle was making unusual sounds when turning and the passenger side door would not close automatically. At the dealership I found out that the rack and pinion steering unit had failed along with the the cable on the passenger side door. On investigation of the water leak the dealership found that the passenger side pillar had not been sealed properly to the roof causing water to run into the van and rot the carpet. While the vehicle is in for repairs the dealership is also replacing the heater/air conditioner blower which is making grinding sounds again.

- Salisbury, MD, USA

problem #2

Nov 152006

Grand Caravan

  • Automatic transmission
  • miles
Gas gauge failure on 2005 Dodge Grand Caravan. Gage reads full when vehicle is serviced with gas and tank is filled. As gas is used the gage will decrease correctly until 1/4 tank is remaining. Gauge then hangs up, showing 1/4 tank, and does not decrease as gas is used below 1/4 tank. This resulted in my daughter-in-law running out of gas while in heavy evening traffic. Luckily, she was able to coast to the side of the road. I have found out from reliable sources (authorized Dodge repair shops) that this gas gage failure is common among the Dodge Caravan's and Grand Caravan's. I feel this is a safety issue and should be investigated for possible recall to prevent any possible injury or death resulting from running out of gas while in heavy traffic.

- Altus, OK, USA

problem #1

Apr 172006

Grand Caravan 6-cyl

  • Automatic transmission
  • 17,916 miles
: the contact stated the exhaust pipe protrudes below the bottom of the vehicle. The child may touch this pipe. Updated 5/10/2006 - the exhaust pipe protrudes below the bottom of the vehicle and is too close to the outside edge (rocker panel). The pipe is located on the right side of the vehicle which is the side the consumer child safety seat is installed. When the sliding door is opened the child could be burned by the pipe. The consumer indicated that the pipe is only like this on the stow and go model Grand Caravan. Updated 5/10/2006 - the parking brake cable had to be replaced and rerouted. The engine ran rough while idling and in park. The fuel gauge was erratic. At 1/4 of a tank or less the needle moves back and forth from empty to 1/4 of a tank.

- Culver City, CA, USA

Not what you are looking for?