hardly worth mentioning
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
92,515 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.

2006 Dodge Grand Caravan fuel system problems

fuel system problem

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2006 Dodge Grand Caravan Owner Comments (Page 1 of 2)

problem #23

May 312016

Grand Caravan

  • 80,000 miles


After fueling my 2006 Dodge Caravan it will stall, or sputter to almost stalling then rev up and almost stall again several times. After a few times of stalling and sputtering it then runs fine. The problem is that this happens usually right after pulling out of the gas station, which usually involves pulling out into traffic. Two times this happened, before I know better now, it happened after pulling out onto the road and stalling in the middle of 4 lane roads. Luckily the first time there was no traffic and the second time I was going downhill on a straight road and was able to coast until I got the van started. Although I am aware of the problem now, this could be dangerous. Also this is a business vehicle and people other than myself drive the vehicle. My employees may not be able to react to a stall in the middle of a road as I am.

- Wilmington, DE, USA

problem #22

May 082016

Grand Caravan

  • 155,000 miles
Engine rough idle after fueling and occasionally stalls on road

- White Bear Twp, MN, USA

problem #21

Dec 082015

Grand Caravan

  • 150,000 miles
The contact owns a 2006 Dodge Grand Caravan. While driving at 30 mph, the vehicle stalled. The contact stated that the failure occurred immediately after the fuel tank was filled. The vehicle was not diagnosed nor repaired. The manufacturer was notified of the failure. The approximate failure mileage was 150,000.

- Effingham, IL, USA

problem #20

Jan 142016

Grand Caravan

  • 10,003 miles


I have a 2006 Grand Caravan and lately, everytime I fill it up, it stalls out on me a few times. I almost got hit pulling out onto a highway last week.I called the dealership and he was aware of the problem. Said I should not fill the tank because it would overflow on some valve causing the stalling. He had other customers complain. My question is, why is this not fixed?. I need to fill my tank as I travel a lot. I don't want to stop and get gas often. And I sure don't want to get hit trying to leave the gas station. I got online and looked up complaints. Here is just one list I found. en.allexperts.com/Q/Chrysler-repair-807/F/stalling-refueling.htm with this being a major problem with so many, I think Chrysler should have a recall for the safety of so many people. I never had a problem until recently so this tells me, something is faulty in the gas tank. As soon as I fill it and drive off, it stalls, once it's driven a while, it works fine. I think the dealership is wrong to cover up the real problem.

- New Carlisle, OH, USA

problem #19

Feb 052015

Grand Caravan

  • 71,000 miles
The contact owns a 2006 Dodge Grand Caravan. The contact stated that the vehicle stalled without warning. The contact mentioned that the failure recurred after the vehicle was refueled. The vehicle was restarted. The failure recurred numerous times. An independent mechanic diagnosed the vehicle and stated that the fuel tank needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was 71,000.......updated 04/01/16

- Calverton, NY, USA

problem #18

Jan 232016

Grand Caravan

  • 87,000 miles
Upon refueling, the vehicle experiences a delayed stall, meaning that the vehicle does start without hesitation; however, within a few yards of driving, the vehicle stalls. More specifically, it stalls upon braking to yield or turn just after fueling. Once the vehicle stalls, it can be restarted and the problem does not present itself again until the next fill up. This is a safety issue as the vehicle may stall in the middle of entering a busy street potentially causing an accident. This gets progressively worse with each fill up because although the engine does turn over, it takes longer to do so each time and may eventually not turn over at all. Internet research and diagnostic from a certified mechanic indicate that it is the liquid separator valve. Further research shows that this is a common problem with Chrysler minivans. The valve cannot be replaced without replacing the entire gas tank. The valve cannot be purchased separately. Because the valve is considered an emissions problem and the gas tank is not, some warranty companies will not cover the replacement. This places the consumer at risk because the high cost may not be feasible and the consumer may opt to continue to deal with the vehicle stalling in lieu of repairs. If this is a common problem with these vehicles, Chrysler should either recall or allow the valve to be purchased separately.

- Orion, IL, USA

problem #17

Oct 112015

Grand Caravan

  • 55,000 miles


Post refueling stalls. While going on long trips, after refueling in the rest areas, the minivan stalls while entering the highway causing me to panic while avoiding high speed traffic going by. This happen many time during a trip to Florida from Indiana.

- Avon, IN, USA

problem #16

Sep 012013

Grand Caravan

  • 25,000 miles
I came across the NHTSA action number DP14002 when looking for internet info about other problems with the 2006 Grand Caravan. The NHTSA summary describes an ongoing problem that we have with this mini-van: If you completely fill the fuel tank you are quite likely to have the vehicle stall within the first quarter-mile of driving. I am sorry see that this action has been closed!

- Fort Wayne, IN, USA

problem #15

Aug 012014

Grand Caravan 6-cyl

  • 117,000 miles
This problem started in August of 2014 but it is ongoing and happened as recently as March 27, 2015. Every time I fill up the gas tank on my 2006 Dodge Grand Caravan, the car stalls out while we are driving. Eventually, we are able to start the van back up and keep driving. After that, it drives fine until we fill up the tank again. One time we stalled out and the van did not start back up so we replaced the fuel pump. The van started back up but the issue returned again. It happens every time we fill up. This seems to be an ongoing issue that many people have. I believe it is related to defect petition dp 14-002. www-ODI.NHTSA.dot.gov/acms/cs/jaxrs/download/doc/ucm461759/inoa-DP14002-5470.pdf. I believe that Dodge needs to issue a recall and fix the fuel tanks which contain the faulty fuel valves causing this problem.

- Fort Worth, TX, USA

problem #14

Mar 032014

Grand Caravan 6-cyl

  • 90,000 miles
Starting about a year ago, my 2006 Dodge Grand Caravan engine stalls after refueling, usually when making a turn, but sometimes when just driving straight. A few times I have almost been in serious accidents because of it, the most serious stall occurred in a busy intersection. The stalling occurs after about 90% of my fill-up times. It occurs on the first drive after refueling but I don't know when it will happen. I called Dodge and spoke to jarred on 3/2/2015 at 1:00pm but he would not say if Dodge/Chrysler has any knowledge of the problem. He just said that it is not on their recall list. I hope that the NHTSA can push Dodge to create a recall for this problem, which I believe is a defective gas tank or part of the gas tank.

- Massapequa, NY, USA

problem #13

Sep 052013

Grand Caravan 6-cyl

  • 106,000 miles


After fueling, the vehicle with surge and often stall with need for restart. Very frequently it does this when taking off from a stop sign which can cause a stall in the middle of an intersection.

- Hastings, NE, USA

problem #12

Jan 312015

Grand Caravan 6-cyl

  • 84,800 miles
After filling up with gas engine stalled approximately 1/2 mile from the gas station. Had to coast to side of the road without power steering. Placed engine in park, turned of key and restarted. Engine ran rough had to depress accelerator for additional gas. Once restarted engine ran fine for the rest of the trip. This same problem also occurred in early January 1/03/2015 after filling up with gas. Not only is this an inconvenience, but very dangerous in heavy traffic scenarios.

- Byron, IL, USA

problem #11

Jan 112015

Grand Caravan 6-cyl

  • 135,000 miles
Refueled vehicle normally. Drove 1 mile, while turning corner the engine stalled completely, steering became sluggish. This has happening approximately 50% of the time after we refuel the Caravan. It is extremely dangerous as we lose control of the vehicle.

- Bogart, GA, USA

problem #10

Mar 032014

Grand Caravan 6-cyl

  • 105,000 miles
Investigation: Dp 14-002; prompted by: Defect petition; date opened: 09/05/2014; investigator: [xxx]; reviewer: [xxx]; approver: [xxx]; subject: Engine stall after refueling. Please include me in the above mentioned complaint/investigation # dp 14-002. After refueling, my engine stalls about 1 to 2 minutes after starting almost every time I fill-up with fuel. When the fueling nozzle trips for the first time, I do not attempt to continue adding more fuel and possibly overfilling the fuel tank. I have been caught in heavy traffic at times with the engine stalling and it takes 2 to 3 attempts to restart the vehicle. This is very dangerous! now after refueling, I pull away from the pumps and park out of the way and allow the engine to stall. After attempting to restart several times, the engine will misfire for about 30 to 45 seconds, then the engine will smooth out and run fine until the next refueling. I want to thank you in advance for all of your help in this matter. Information redacted pursuant to the Freedom Of Information Act (FOIA), 5 U.S.C. 552(B)(6).

- Yorktown, VA, USA

problem #9

Dec 012014

Grand Caravan 6-cyl

  • 126,400 miles
I was picking up a machine in Georgia, and I had to stop and get gas. I filled up with gas drove onto the turnpike and the car stalled and a truck almost hit my car as my car was coasting to get it off the highway. He hit his brakes and squealed up to my vehicle. This situation could kill someone and I read hundreds of complaints from people online. This happens on every fill up since.

- Dubois , PA, USA

problem #8

Nov 202014

Grand Caravan 6-cyl

  • 220,000 miles
Over the last several weeks my 2006 Dodge Grand Caravan with a 3.8 liter engine will stall out several times after refueling. It will restart & stall several times before the problem seems to rectify itself. All power assisted steering is lost and the vehicle becomes difficult to steer safely. Power braking is also affected. There have been a couple of occasions where I have been turning into traffic and had the vehicle stall. One time I was unable to complete the turn and stay in my lane. On one occasion I breached the lane to my left. While traffic was traveling in the same direction I was, another motorist had to slam on the brakes to avoid hitting me.

- Lake Orion, MI, USA

problem #7

Aug 112012

Grand Caravan

  • 95,213 miles
Filled fuel tank right off I24 in tn. Car stalled on entrance ramp to highway. Drifted to side and engine restarted quickly. This now happens almost every time the tank is filled. Around town I can cope by not filling the tank, but very inconvenient and very dangerous on trips especially on highways. We are not talking about overfilling the tank, but just filling to point when pump shuts off. When engine stalls, not only is there an immediate loss of momentum, the power steering system quits, but the brakes become useless. Every time this happens, I just wait for someone behind me to not slow down in time and rear-end me. Luckily, I have not been in the fast or middle lane when it stalls, because of possibly not being able to get to the shoulder to restart it. I am also paranoid that if I try to mess with putting it into neutral and fooling around with the key, I will become a very distracted driver. Chrysler's answer is to replace fuel tank at a cost of $1200. If I could afford that then I wouldn't be driving a 2006 automobile.

- Hopkinsville, KY, USA

problem #6

Oct 072014

Grand Caravan 6-cyl

  • 64,000 miles
After filling the tank with gas, the van engine runs rough and then stalls out. This has happened numerous times over the past three to four years. When it happened on tues, October 7, 2014, I had just pulled out of the gas station and was getting ready to cross a busy intersection when the car stalled. I had to quickly put it in to park and restart. Scared me to death. Again, this has happened at least fifty times to me. We have taken it to the dealership and they can never get the problem to happen for them which makes sense because it is only going to happen after refueling.

- Bloomington, IL, USA

problem #5

Aug 022013

Grand Caravan

  • 50,000 miles
The contact owns a 2006 Dodge Grand Caravan. The contact stated that when refueling to a half or full fuel tank, the vehicle stalled. The failure occurred on numerous occasions. Additionally, the contact stated that the key failed to turn in order to start the vehicle. The vehicle was taken to an independent mechanic, who diagnosed that a sensor failed within the fuel tank and the fuel tank needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The approximate failure mileage was 50,000.

- Apollo, PA, USA

problem #4

Sep 102014

Grand Caravan 6-cyl

  • 108,437 miles
Van stalls after filling the Grand Caravan with fuel. Loses steering and speed.

- Dearborn Heights, MI, USA

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