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?


pretty bad
Typical Repair Cost:
Average Mileage:
74,363 miles
Total Complaints:
3 complaints

Most Common Solutions:

  1. replace tank (2 reports)
  2. not sure (1 reports)
2004 Dodge Durango fuel system problems

fuel system problem

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2004 Dodge Durango Owner Comments

problem #3

Mar 152013

Durango EXT 4.7L V8

  • Automatic transmission
  • 100,000 miles


Whenever we fill the tank completely, we experience fuel puddling under the gas tank. So far, we have an evaporative emissions issue with CheckEngine light coming on sometimes. Worried that this could be a safety issue or a fuel loss issue, esp. in warmer months. Any ideas as to what could be causing this?

- , Slatington, PA, USA

problem #2

Oct 162012

Durango Limited 5.7L Hemi V8 Magnum

  • Automatic transmission
  • 42,090 miles

my Malfunction Indicator Light came on and stayed on. I checked my gas cap and confirmed it was on tight. I scheduled the diagnosis for the next day. They found an emissions leak, probably around the fuel pump where it connects to the fuel tank. They did the air test and smoke test. Upon checking with a mirror, the service tech saw a lot of rust on top of the fuel tank. Their suggestion was to lower the tank to see all that is damaged. This revealed that the tank was severely rusted and caved in, this caused the fuel pump to crack. Now I have to get a new fuel pump and fuel tank. The service manager did say that he believes the new tanks are plastic. He said that there was nothing I could do to have prevented this. I am very discouraged as we meticulously care for our vehicles and I don't understand how this can happen. I guess we could go with used parts but I hate to do that on a vehicle that isn't that old. I have a 23 year old Jeep that doesn't have a rusty fuel tank. I will have this repaired because this is our family travel vehicle and we love the power.

- , Agawam, MA, US

problem #1

Sep 132010

Durango LTD 5.7L

  • Automatic transmission
  • 81,000 miles

Check engine light came on ( latest of many, many times) and dealer traced it to low emissions system pressure caused by a hole rusted through the top of the gas tank near the fuel pump connection. The support straps for the tank are also rusty and need to be replaced. This problem is a safety hazard and should not happen on such a young vehicle. I have two other cars that are much older (not Dodge) which have had the same operating conditions and have not experienced any such issues. Dodge complaint dept (800-992-1997) has assigned a case number and referred the problem to the local district manager - no resolution yet.

- , Trumbull, CT, US

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