hardly worth mentioning
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
81,334 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 Dodge Caravan fuel system problems

fuel system problem

Find something helpful? Spread the word.
Get notified about new defects, investigations, recalls & lawsuits for the 2004 Dodge Caravan:

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

2004 Dodge Caravan Owner Comments

problem #11

Jan 202016


  • 145,000 miles


Engine often hesitates after you have driven a few blocks after refueling. This form asks for a single specific date but this problem has happened every few weeks for the last year or so. Depending upon the traffic situation when the hesitation occurs, and accident could easily occur. My mechanic says that the liquid/vapor separator valve on the gas tank is not operating properly. This valve is a part of the tank and cannot be replaced as a separate item, so the cost of the repair is substantial. A brief search on the internet indicates that many other owners of Dodge Caravan manufactured between about 2004 and 2007 are reporting this same problem.

- Clemson, SC, USA

problem #10

Mar 192015


  • 118,000 miles
I purchased my vehicle in the fall of 2013 and am starting to come to the conclusion that every time I fill my gas tank up my vehicle shuts off! today I filled up my gas tank. My children were in the back seat and when I pulled out into the highway the van shut off and the steering wheel locked up! I had no control over the vehicle. This seems to be a common problem with these vans and something needs to be done before someone gets hurt! I can't fill my gas tank up because of this issue.

- Goldsboro, NC, USA

problem #9

Dec 112014


  • 155,755 miles
The contact owns a 2004 Dodge Caravan. The contact stated that the vehicle was leaking fuel. The vehicle was taken to an independent mechanic who stated that there was a leak in the fuel pump due to corrosion. As a result, the fuel pump assembly needed to be replaced. The vehicle was repaired. The manufacturer was notified of the failure. The approximate failure mileage was 155,755.

- Portsmouth, VA, USA

problem #8

Jun 132012


  • 75,000 miles


Every time vehicle is fueled up, the vehicle putters and shuts off, causing all power steering to lock up while driving. Occurs the first couple miles.

- Green Isle, MN, USA

problem #7

Sep 012008


  • 39,000 miles
Not 100% but probably 40% - 60% of the time I refuel - especially a full tank - the car will tend to hesitate and stall within the first 90 seconds of getting back on the road. Seems like it has not done it a lot lately but I just had some work done by the local Dodge dealer including new wires and plugs. When I left the dealership it ran fine. I put in probably 3/4 tank of gas in it and it began hesitating and stalling worse than it had in some time. The weather was also quite a bit cooler than it had been in 6 months. I also read an article in usa today about this issue which I have been experiencing since 2007 when I purchased the car used. I have had the dealer look at it in the past and the could identify nothing specific. Figured I would register the complaint since I heard others were having the same issue.

- Owosso, MI, USA

problem #6

Apr 182012


  • 96,000 miles
As mentioned by several other postings, the Caravan engine will stall out after the gas tank is filled. This happens almost every time the vehicle is fueled. It will stall out within a few minutes of driving after leaving the gas station. It has stalled out in traffic, at stop lights, and now I avoid traveling on the roadway for several minutes after fueling if possible, choosing instead to travel through parking lots or back roads before entering any main arteries. A service repairman at the dealership said he had never heard of such a thing and had no idea what the problem could be. Another mechanic mentioned it might be a valve in the top of the tank that is defective but the only repair is to replace the whole gas tank as the part is not a separate piece. Based on my own online research, I think this is a defect with this make and model.

- Damascus, MD, USA

problem #5

Sep 072009


  • 40,000 miles


After fueling the vehicle stalls numberious times in traffic causing a hazzard. This would be exceptabe however there seem to be many of the vehicle that does the same thing see forum.chryslerminivan.net.

- North Adams, MA, USA

problem #4

Aug 232013


  • 101,224 miles
The contact owns a 2004 Dodge Caravan. The contact stated that while at a stop, the vehicle stalled as the check engine warning light illuminated. The vehicle was taken to a dealer where it was diagnosed that the fuel pump needed to be replaced. The manufacturer was not notified of the failure. The vehicle was not repaired. The approximate failure and current mileage was 101,224. The VIN was not available.

- Montgomery, AL, USA

problem #3

May 132008


  • 38,000 miles
The contact owns a 2004 Dodge Caravan. The contact stated that over the course of five years, whenever he filled the fuel tank the vehicle would stall immediately after. The failure recurred numerous times. The vehicle was taken to a dealer on three different occasions but the no cause for the failure was determined. The vehicle was not repaired. The failure mileage was 38,000 and the current mileage was 91,000.

- Stone Mountain, GA, USA

problem #2

Jun 042012

Caravan 6-cyl

  • Automatic transmission
  • 51,000 miles
My family began noticing a gas smell several months ago. It was more noticeable when exiting the vehicle and when in a closed garage. At first I thought it might be from some gas spill on fueling. I did not see any leaks on the ground or in the engine area. I just had the van serviced at the dealer and was told there was a gas leak. Upon closer inspection it appears there is a very slow leak (seepage) coming at the connection off the fuel pump and fuel line. This looks like a twist-off connection. The dealer told me it would cost $96/hr to pinpoint and diagnosis the exact problem. I just found another person on the web with the exact same complaint. I have not yet had an "exact diagnosis" or repair made. Updated 03/26/13 the consumer stated the fuel pump was inspected and replaced by a local dealer. They confirmed the pump was leaking through a cracked housing. The gas tank was stained by the fuel leaking down upon it.

- Wallingford, CT, USA

problem #1

Aug 112009

Caravan 6-cyl

  • 35,700 miles
When one drives away after refueling the gas tank the vehicle quits running. It will restart. This will happen for the first ten miles or so. Other Dodge are having the same problem.

- North Adams, MA, USA

Not what you are looking for?