hardly worth mentioning
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
92,000 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

problem #8

Nov 152012

Grand Caravan 6-cyl

  • 80,000 miles


Every time I fill up the van, as soon as I pull out of the gas station it will idle rough, hesitate, or die all together. I could have 1/2 tank and add maybe 5 gal of gas and it will do the same thing. I saw online that I am not the only one that had this issue. It ranges for different years and come to find our it has to do with a valve above the tank and cant be replaced singly but the whole tank for $1600 plus labor. This is a safety issue because this thing has happen in the middle of an intersection while turning. I called melloy Dodge here in albuquerque nm and they right shot me down about as quick it took to dial the phone number.

- Albuquerque , NM, USA

problem #7

Aug 152013

Grand Caravan 6-cyl

  • 180,000 miles
Noticed fuel smell and vehicle stalling or hesitating after fueling, found fuel leak coming from very small cracks on fuel pump housing top located on the passenger side of the van close to the exhaust system.

- Hastings, FL, USA

problem #6

Sep 072007

Grand Caravan 6-cyl

  • miles
This incident occurs every time I fill up with fuel. It began at approximately 35,000 miles and continues until this day at about 116,000 miles. Incident description: I enter the gas station. I fill up with fuel until the pump stops, not a "top-off". I start the ignition and begin to drive away. The engine stutters and sometimes stalls completely. After a short distance, 3 miles or so, it runs normally. Recently after my knee surgery, my wife was driving and pulled out into traffic, left hand turn, after a refuel. We were trying high-test ethanol free gasoline. Well she made it into the center turning lane and waited her turn. When an opening arrived she pressed the accelerator and the van started and failed completely, leaving us half-way in the lane for oncoming traffic. Thankfully the oncoming traffic slowed as they blew their horns and she was able to restart the van and begin to drive. This was a most miserable experience especially since we had all three of our small children in the van with us. Something really needs to be done to correct this ongoing and dangerous issue.

- Pensacola, FL, USA

problem #5

May 072010

Grand Caravan 6-cyl

  • 100,000 miles


The 3.8L engine stalls after almost every fuel fill-up and began in early 2010. Within 1-2 miles after a fuel up, the vehicle will buck and sputter and often turn off completely. It gets better after 3-5 miles. It apparently is a known issue with many Dodge owners, not just minivans. I had two 2006 Dodge chargers (R/T and srt8) that both did the same thing. I no longer own the chargers but still have the 2004 Caravan. This a dangerous and unpredictable issue that has something to do with the tank mounted vapor separation valve and the vapor return system. The vehicle is not "topped off" when fueling which has been known to create the issue. Thanks.

- Raleigh, NC, USA

problem #4

Sep 172010

Grand Caravan 6-cyl

  • 112,000 miles
Our 2004 Dodge Grand Caravan will stall out driving down the road if you fill the gas tank until the gas pump nozzles stops automatically. The only way to stop this is to replace the gas tank because of a bad valve in the top of the tank in the emissions system. I found this information on line. It has done it several times and we now under fill the tank which is not easy to do.

- Peru, NY, USA

problem #3

Jan 122010

Grand Caravan

  • 115,000 miles
2004 Dodge Grand Caravan stalls after filling up with fuel, hard to start back up, dealer did not have answer, already changed gas cap and car still stalls about 80% of the time after filling up..

- Kennan, WI, USA

problem #2

Jul 162009

Grand Caravan

  • 90,000 miles
The contact owns a 2004 Dodge Grand Caravan. The contact stated that each time she added fuel to her vehicle it stalled. All of the gears illuminated and the brakes locked. The vehicle was towed to a mechanic and then to the dealer but they could not duplicate the failure. The vehicle was not repaired. The manufacturer was not called. The VIN was unavailable. The failure mileage was 90,000.

- Lakewood, NJ, USA

problem #1

Jun 222009

Grand Caravan

  • 59,000 miles
2004 Dodge Grand Caravan fuel tank vapor float vent failure. Vehicle has 59,000 miles. After fueling vehicle it will stall intermittently at stop signs and on open highway without warning, because fuel is getting into the engine and flooding engine out via the tank venting vapor system. When fueling, a float in the orvr (onboard refueling vapor recovery) valve is designed to rises and seals the tank vent causing pressure build, backing fuel up into the fill neck and shutting it off. The orvr is apparently not sealing completely or at all, allowing liquid fuel to pass into the vent line to the vapor canister and then engine. The valve is plastic welded to the tank, which requires the tank to be replaced. Major safety issue because the power steering system stops when engine stops and vehicle is not able to be steered without the power steering aid. Vapor system failure fully described at: www.justanswer.com/questions/1ob81-2005-Dodge-Caravan-stalls presently only keeping tank fuel at a maximum of 3/4 full to avoid flooding the vapor vent system.

- Burke , VA, USA

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