hardly worth mentioning
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
104,720 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 Grand Caravan fuel system problems

fuel system problem

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2004 Dodge Grand Caravan Owner Comments (Page 1 of 2)

problem #25

Aug 302019

Grand Caravan

  • 260,000 miles


Hairline cracks in fuel pump outlet just before connecting to fuel line leads to strong fuel smell and fuel vapors all around vehicle. Fuel pump needs replacement to repair this dangerous condition. Highly suggest different fuel pump design that is not prone to hairline cracks and potential fire hazard as fuel leak is about one foot away from a hot muffler and a tossed cigarette or other spark could cause a fire or explosion.

- Saint Marys, WV, USA

problem #24

Nov 032016

Grand Caravan

  • 115,000 miles
After filling the gas tank, within a few miles the vehicle will stall. Dodge already has extended the warranty on the fuel tank of vehicle built after September 2003 but mine was built August 5 2003 so it is outside their window. This is a very dangerous issue because it has happened to me on the highway at 55 miles an hour and I then have no power and need to get out of the way of traffic that is going to run me over.

- Wappingers Fals, NY, USA

problem #23

Nov 012014

Grand Caravan

  • 150,000 miles
Every time we fill the fuel tank the Caravan cuts off and rides very rough. The recall on the Dodge Caravan was on vans build starting on 09/01/2003 my Caravan was built on 09/29/2013.

- Mechanicsville, MD, USA

problem #22

Apr 202012

Grand Caravan

  • 70,000 miles


The contact owns a 2004 Dodge Grand Caravan. The contact stated that after refueling the vehicle, it stalled without warning. After several attempts the vehicle was able to restart but the failure recurred. The vehicle was not diagnosed or repaired. The manufacturer was notified of the failure. The approximate failure mileage was 70,000.

- Mechanicsville, MD, USA

problem #21

Jan 112016

Grand Caravan

  • 160,000 miles
Engine stalls out 10 or 15 seconds after filling the gas tank. Usually on the highway you are turning on to. Its been doing this for a couple of years.

- Greensboro, NC, USA

problem #20

May 252013

Grand Caravan

  • 75,000 miles
The vehicle stalls out after filling at the gas station. Reportedly due to an issue with the check valve and requires the entire fuel tank to be replaced.

- Grand Forks, ND, USA

problem #19

Jun 142014

Grand Caravan

  • 100,000 miles


The contact owns a 2004 Dodge Grand Caravan. While driving 45 mph, the temperature gauge on the instrument panel started going to the red side; indicating that the vehicle was having trouble regulating the engine cooling system. The contact also stated that there was a strong odor of fuel entering the vehicle. The vehicle was taken to an independent mechanic where it was diagnosed that the fuel pump and carbon filter needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure. The failure mileage was 100,000.

- Baytown, TX, USA

problem #18

May 292015

Grand Caravan

  • 115,000 miles
I went to the gas station and filled my gas tank, not topping it off, and as soon as I turned out of the station on a major road the vehicle stalled and almost resulting in an accident. After a quick restart the van ran fine and I was able to drive from nashville, tn to atlanta, ga with no problems. But when I filled up again in atlanta, right after pulling out of the gas station the vehicle stalled again, in the middle of a busy intersection. This problem is widely reported across Dodge and Chrysler vans, with over 100 complaints on this website. I'm hoping this issue with the gas tank/sensors will be address. Thank you.

- Antioch, TN, USA

problem #17

May 012015

Grand Caravan

  • 33,000 miles
After fueling the check engine light is now on and indicates an emissions leak which causes vapors to now build up inside the van after every refueling. If filled to capacity the vehicle will also stutter and sometimes completely stall shortly after fueling.

- Stronghurst, IL, USA

problem #16

Aug 152014

Grand Caravan

  • 109,000 miles
Every time I fill my tank (I do not top off), within a few minutes of leaving the station, the van dies. It normally re-starts, but it takes quite a lot of gas pedal pumping. This is dangerous when it happens in the middle of an intersection. I had the fuel pump and filter replaced and that did not solve the problem. Now I understand that the valve on top of the tank is at fault, but you have to replace the entire tank. This is a design flaw and needs to be corrected.

- Central Point, OR, USA

problem #15

Apr 102015

Grand Caravan 6-cyl

  • 108,000 miles


While making left the vehicle stalled while in motion in the middle of major intersection. After a 20 or so seconds, the vehicle engine turned on. Another incident, approximately a year ago, while traveling 60+ miles on major interstate, the vehicle again shut down while in motion. I had to coast the vehicle, with loss of power, to median on the interstate. After about a minute or so, the vehicle turned on. Always upon filling the gas tank, the vehicle stalls while exiting the gas station or shortly thereafter. After a minute, the vehicle is able to turn back on.

- Clearwater, FL, USA

problem #14

Mar 302015

Grand Caravan 6-cyl

  • 124,000 miles
Car shuts off after filling the gas tank. This has happened several times. Always on the road and in traffic.

- Byron Center, MI, USA

problem #13

Jan 222015

Grand Caravan

  • 150,000 miles
After filling my '04 Grand Caravan with fuel and attempting to leave the pump my Caravan shuts off. This has been on an ongoing issue for over 2 years. After several repair attempts I was told today that the vapor separator valve located on top of the gas tank is faulty. A valve that Dodge does not make available for repair. The only "fix" that is offered is to replace the entire tank of which I was told today would be $1600.

- South Mills, NC, USA

problem #12

Jul 102014

Grand Caravan

  • miles
The fuel pump has hair line fractures in multiple places of fuel pump in and is leaking gas looks like its been there for awhile but I just noticed it in July iv been reading up on it and there's. been alot of people with the same problem with 04 Dodge grandcare vans SXT and others models also...... thanks.

- Terre Haute, IN, USA

problem #11

Oct 122011

Grand Caravan 6-cyl

  • 75,000 miles
After taking on gas, engine will sometimes stumble and most of the time quit running. Tried not over filling it and it still will just die sometime after taking on gas. On two occasions, it did this after hitting highway speeds. It would suddenly lose power and you had to pull off the road. It would normally start back up and have no more problems until next fill up. Because of this, we don't fill up and hit the road. We drive around before driving at highway speeds. Once, it died in front of several cars and a big truck had to brake hard and swerve off the road. So far, there has not been any known accidents but feel it is a matter of time before someone gets hurt. The mechanic said it was something wrong with a valve in gas tank and that you can't buy the part. We don't loan our van to the kids anymore since my oldest daughter almost caused a wreck and almost got hit when the van lost power.

- Virginia Beach , VA, USA

problem #10

Jun 012010

Grand Caravan 6-cyl

  • 100,000 miles
For the past four years or so, almost every time after filling up the gas tank, the 2004 Dodge Grand Caravan anniversary edition stalls. I can be just pulling away from the pump when it happens, or stopped at a stop light within a few minutes from leaving the gas station. You can feel the car 'jump' like someone is pressing the gas pedal quickly and it jerks the van a bit forward. Then it stalls. It takes a few turns of the key and pressing the gas pedal very quickly and forcefully to get it started again. I have gotten into the habit of driving the van around a parking lot for a few minutes until it feels back to normal before pulling out into traffic, as I'm concerned it will stall out in the middle of traffic. This only happens right after filling up the gas tank. It concerns me now more than ever since my son is learning how to drive and I want him to be safe.

- Greensburg, PA, USA

problem #9

Sep 102014

Grand Caravan

  • 176,000 miles
Engine started missing, vibrations from engine. Diagnosis electrical fault. Wiring harness brittle form harness being placed on, over and next, snaked around exhaust manifold, causing premature wiring failure. Fuel injector wiring harness unshielded in side of intake manifold / plenum. Wiring harness poorly shielded. This is a deliberate, intentional design / engineering to snake wiring harness around exhaust manifold. Causing wiring harness failure. Using sub-standard wiring components and not using shielding to cause pre-mature failure. Installing PCM (computer) in wheel well for pre-mature failure exposed to salt, road debris, water, etc. PCM installed in open area of vehicle prone to failure. Consequential safety issues.

- Pompano Beach, FL, USA

problem #8

Sep 022010

Grand Caravan

  • 115,000 miles
The contact owns a 2004 Dodge Grand Caravan. The contact stated that the vehicle would stall immediately after refueling. The contact indicated that the failure had occurred on multiple occasions and in some instances the vehicle would stall up to two times before operating as normal. The manufacturer was notified of the failure but no solution was offered. The failure mileage was 115,000.

- Deerborn Heights, MI, USA

problem #7

Aug 012012

Grand Caravan

  • 100,000 miles
Beginning around August 2012, my 2004 Dodge Grand Caravan anniversary edition began to sputter and stall if I ever filled the gas tank completely. If I did not continue to feed gas to the engine, the engine would stall. At stoplights I would need to put the car in park and rev the gas and then sit in park until I was able to move. This would continue for approx 2-3 miles. In summer 2013 it began happening even if the car was not filled to capacity. Repair shops tell me it's the type of gas or there is water in the gas line, but my research tells me this is a known Caravan issue. My requests for repair investigations are not taken seriously. So my solution is to never fill the car beyond 3/4 tank - super inconvenient. As a result, the sputtering does not happen as much any more, but the situation is dangerous and scary. I am just waiting for the engine to fail in the middle of a busy road simply because I've gotten fuel.

- Westfield, NJ, USA

problem #6

Oct 012013

Grand Caravan

  • 155,000 miles
My van left small fuel marks in driveway, I investigated it physically and found fuel to be leaking by fuel pump housing near a fuel line, I assumed it was leaking from the O-rings on quick disconnect line. I replaced O-rings and the problem still exists. I googled the issue and to my surprise there are many similar issues, people explaining how their vehicles where leaking in the same location. After browsing I found a website where there was a picture showing fractures on the housing near the fuel line that I had worked on. Sure enough I rechecked my vehicle and there were the fractures. Leaking fuel. I just wanted to post this on this website to inform other owners, that if they smell fuel from their van, they should get this issue checked asap. This is a real hazard, and could be really dangerous.

- San Antonio, TX, USA

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