Notes: The second generation Durango was introduced in 2004 and instantly came under fire for, well, catching on fire.

From 2004-2006 electrical overloading in the driver's side instrument panel caused numerous reports of interior fires. The interior infernos became so commonplace that Chrysler eventually issued a recall.

The problems didn't stop there, however. Owners of the recalled vehicles complained about being treated unfairly and given take-it-or-leave-it low ball settlement offers. "They offered me $2000 under NADA retail as a settlement," said one owner, "and have been rude and hostile to deal with." Nothing says awesome service like treating your customers rudely after their cars have caught on fire.

Have we mentioned all the reports of complete engine failure due to oil sludge?


hardly worth mentioning
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
60,751 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 Durango fuel system problems

fuel system problem

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2004 Dodge Durango Owner Comments

problem #11

Jul 112011

Durango 8-cyl

  • 70,000 miles


Gas spills out when filling the tank. Rust from gas spills.

- Harleysville, PA, USA

problem #10

Feb 012014

Durango 8-cyl

  • 190,000 miles
The fuel overflow does not work and allows for fuel to spill all over the car. This results in lots of fuel on the car and on the ground. You can never use the automatic fuel filler on pumps. I have even gotten fuel as high up as my face when it splashes out. This has resulted in rust on the left rear quarter panel and as well as a very unsafe fueling area.

- Winchester, VA, USA

problem #9

Oct 092013

Durango 8-cyl

  • 101,763 miles
My truck was parked in the driveway, it was raining and then the lights started flickering without the keys being in the ignition. I tried to move the truck to the inside of the garage and the smoke came out of the hood and from under the dash. I turned the truck off and the engine remained running, we had to call the fire department because it was smoking and the keys were off. The fire department came and removed the battery and said it may be a short when it rained. The truck is in the garage I cant drive it when it rains because water goes in to the truck from the front I can actually see water leaking into the floor. I owned the truck for 3 years and never had this problem until it reached 100,000 miles.

- Aurora, IL, USA

problem #8

May 102011

Durango 4WD 8-cyl

  • 60,000 miles


When filling with gas the fuel tank spews out gasoline.

- Harleysville, PA, USA

problem #7

Sep 242011


  • miles
Needing more info on just what does the gas cap do. So far I've had my engine light come on, and was told it was because the gas cap wasn't tightened. My latest discovery, I got in my vehicle, turned on the ignition, and the car eventually died, with no further turnover. I got out of the vehicle, thought of checking the gas cap, made a few turns, and got back into my vehicle, and, it turned over without difficulty. What other features does this item have that I should be aware of?

- Tunkhannock, PA, USA

problem #6

Oct 072004


  • 10,000 miles
The contact owns a 2004 Dodge Durango. While fueling the vehicle, gasoline would spill out of the tank. The failure occurred everytime the vehicle was fueled. The vehicle had not been inspected or repaired. The failure mileage was approximately 10,000 and the current mileage was approximately 97,000.

- Menasha, WI, USA

problem #5

Sep 042009


  • 60,000 miles


I have a 2004 Dodge Durango. With absolutely no warning, my electronic throttle control light began flashing and the car died. Didn't even have time to pull over and out of traffic. Had to have it towed home. Holiday weekend, so no dealership was open. Then had it towed to dealership....both tows cost over $200 total. It has now been at the dealership for 2 days. They cant find anything wrong with it. They tell me they think it is "electrical" so they are checking all wires. I am looking at a huge repair bill (on top of the already huge tow fees.) now answer this.....I typed in just a few keywords and found hundreds of posts with the same exact issue. If there are so many 04-05 Dodge Durangos with the same problem.......(there was even a nts investigation) why then does the Dodge dealership claim to have "never seen this before""???? and with the safety issue it poses, why have they not issued another investigation and/or recall??" god forbid it happens again (after I pay a huge repair bill that will not address the issue) and I have my 4 kids in the car!! then Dodge will wish they listened to the american people and fixed a problem they know exists!! they need to "own up", people will be killed in related accidents......what a shame they can get away with this.

- Gilbert, AZ, USA

problem #4

Mar 212009


  • 31,500 miles
When I fill the vehicle with gas the gas starts spitting out at the end of filling resulting in a large amount of gas pouring down the side of the vehicle.

- Fort Myers, FL, USA

problem #3

May 082008

Durango 8-cyl

  • 73,000 miles
The contact owns a 2004 Dodge Durango. Whenever the contact fills the fuel tank, gasoline sprays out of the tank. The fuel nozzle stops when the tank is full; however, fuel continues to spray out of the tank without warning. The manufacturer was notified and the vehicle has not been repaired. The failure mileage was 73,000 and current mileage was 80,000. Updated 3/19/09 the dealer repaired the problem. Updated 03/23/09

- Garden Prairie, IL, USA

problem #2

Jan 092007

Durango 8-cyl

  • Automatic transmission
  • 41,500 miles
Vehicle stalled out on various occasions. Dealer did not find cause, so I had them clean the fuel injectors, and throttle body on vehicle at a cost of $265. Since then, we have not experienced any further problems, todays date is 16 Feb 07.

- Minot, ND, USA

problem #1

Mar 132006

Durango 8-cyl

  • Automatic transmission
  • 30,500 miles
2004 Dodge Durango with the 5.7 hemi erradic idling and stalling at different times.

- Forest City, IA, USA

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