hardly worth mentioning
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
91,738 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 Ram 1500 fuel system problems

fuel system problem

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2004 Dodge Ram 1500 Owner Comments (Page 1 of 2)

problem #22

Aug 042016

Ram 1500

  • 121,380 miles


For a few weeks I would occasionally smell gas fumes. I had the truck visually inspected and the mechanic could find nothing wrong. Then one day I filled the tank. When the tank was full, instead of the pump shutting off the pump began pouring gas onto the ground. This time they dropped the tank to find that the metal collar on top of the tank had rusted away causing the fuel pump to pop up half out of the tank. That was the reason the pump had not shut off. Gas was flowing out of the top of the tank!!. the mechanic told me that if the fuel pump connection had shorted out with the top of the tank open the way it was, me and anyone in the truck would have been blown up!!!. this was a very poor design on Chrysler's part that has the potential to kill people.

- Berlin, MD, USA

problem #21

Jun 012016

Ram 1500

  • 145,000 miles
Fuel tank has metal tabs to lock fuel pump in position. Water can collect with road salts to eat away the locking tabs which allows the fuel to leak out next to hot exhaust which can cause fire. When filling fuel tank the fuel will seep out because the locking tabs no longer hold the pump in place. This leaked fuel can cause fire, and allow fuel to pool under the vehicle causing fuel spills.

- Burlington, NJ, USA

problem #20

Feb 182016

Ram 1500

  • 81,000 miles
The truck stalls at stops and turns after fuel fill

- Barling, AR, USA

problem #19

Jul 142015

Ram 1500

  • 80,000 miles


The contact owns a 2004 Dodge Ram 1500. While driving at 50 mph, the vehicle stalled without warning. The vehicle restarted after a few minutes and was taken to an independent mechanic who diagnosed that the fuel tank needed to be replaced. The failure recurred several times. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was 80,000.

- Newfield, NJ, USA

problem #18

Jun 012013

Ram 1500

  • 75,131 miles
As stated in other complaints, the vehicle will stall after slowing down at intersection of driving in heavy traffic. If you ride the brake and gas, you can keep from stalling. This incident started to happen after a smell of gas vapor smell after filling tank. Researched stalling and gas smell, was led to other scalp notice for hemi gas tank due to ethanol gas causing the rollover valve in the gas tank to expand and not close. When you fill the tank you get liquid gas in the purge vapor canister and line. This giving you the gas smell upon filling. I have stopped filling the tank past 3/4 and have not had the issue since. Kind of disappointed that other hemi models gas tanks were recalled, but not the truck even though it has the same issue.

- Spencerport, NY, USA

problem #17

Jul 012014

Ram 1500

  • 110,000 miles
Stalls at every stop after re fueling

- Bloomington, MN, USA

problem #16

Jul 032015

Ram 1500

  • 177,523 miles


A whining sound started coming from somewhere on the vehicle approx 30 min before the rear end exploded locking the vehicle up and causing the drive shaft to fly across two lanes of heavy holiday traffic. Thank the lord no one was injured or accident was caused due to this failure of a loose pinion nut on the drive shaft. I had it towed to the closest dealership who said it will cost over 4500 dollars not including car rental to get it repaired, the dealer said they contacted the mfg. And they said it was not under the recall. This is a serious and dangerous problem. This vehicle has been dealer maintained since new and should not have experienced this issue without a recall or warning.

- Flowery Branch, GA, USA

problem #15

Mar 292015

Ram 1500

  • 118,000 miles
This has been happening at every fill up. Once I fill the tank, for approximately 20 or so miles after the fillup, my truck tries to stall if I don't rev the engine up really high.. at stop lights or turns, it will stall completely. I have also had to stall on the interstate at speed! once I drive 20 or so miles it stops. I have heard from many owners that it has something to do with a fuel vent or something. Apparently this is quite a common problem that should be looked into. Thank you for your time

- Millstadt, IL, USA

problem #14

Mar 032014

Ram 1500 4WD 8-cyl

  • 22,000 miles
The truck stalls at idle or low speeds after refueling. It happens every time. It is dangerous because the power steering goes out and the truck is very difficult to control. It has happened as I am entering off-ramps and proceeding through intersections. The problem is the vapor/liquid separator valve located at the top of the fuel tank. The valve is designed to prevent liquid fuel from entering the charcoal canister/emissions system. When the valve fails, liquid gas can enter the line and fill the charcoal canister. After refueling, the PCM on the vehicle detects a change in fuel level. Then, when the engine meets certain temperature and driving criteria, the PCM issues a purge command to the charcoal canister to remove the stored gas vapors. It"S at that point that all the liquid gas in the line gets sucked into the charcoal canister. The PCM expects to see gas vapors entering the intake manifold and it is prepared to adjust air/fuel mixtures to compensate. However, it is not prepared to see liquid gas coming into the intake. That"S what causes the engine to stall. Unfortunately, the only fix is to replace the entire gas tank. Chrysler does not sell the vapor/liquid valve as a separate unit. Once the tank is replaced and the charcoal canister purged, the problem goes away. This problem is well-known to Chrysler across a broad range of vehicles, including pickups, minivans and SUVS. Chrysler settled with complainants on some models and years by agreeing to extend the warranty to lifetime, but refuses to acknowledge the problem outside of those vehicles. I am looking at a $1,300 repair bill for a known defective and unsafe part, the replacement for which Chrysler refuses to sell separate from the gas tank itself. I would be deeply grateful for any assistance you may provide.

- Claremont, CA, USA

problem #13

Jul 272012

Ram 1500

  • 84,000 miles
I have a 2004 Dodge Ram 1500 when I get gas and fill up until the pump clicks (I do not top off tank) then upon pulling out of the gas station my truck stalls. If I stop for a red light truck stalls again and it continues to stall every now and then at low speeds, at a complete stop, when braking, slowing down, or at idle and last until I run some gas out of it (about 10 miles or so). Vehicle will start right up with no problem but battery gauge takes a few seconds to rise to operating levels. Transmission also feels like it wants to slip at time of stall. I took it to the dealership but because a code was not thrown it is my issue to deal with (have to drop the gas tank and replace a sensor in the overflow tube $500 plus dollars- which I do not just have lying around). I have avoided topping off at the pump and have to watch the amount of gallons of fuel I put in order not to have the same situation occur again. This is not a valid fix in my opinion. I can see the situation exists with other owners of the same year of my vehicle as well. Why is this not being addressed"!"! this is ridiculous and not to mention very frustrating and dangerous. I have my 3 children in the car with me most of the time and I cringe every time it happens just praying we donot get hit.

- Wylie, TX, USA

problem #12

Jan 072015

Ram 1500 4WD 8-cyl

  • 94,665 miles


I purchased this 2004 Dodge on January 5th 2015. I was to return on January 7th to have different tires & rims installed. On the way I stopped and filled the gas tank. Afterwards every stop sign I came to the vehicle stalled out. It started right back up but continued to stall at every stop sign. The mechanic at redding truck & auto diagnosed that the crank sensor was bad and replaced it at no charge. It ran fine until I filled the gas tank again and started having the same problems with it stalling out. So now if I fill the tank it will stall out until I drive it for several miles or until I run some of the gas out of the tank. I was told not to fill the tank which is not a fix for this problem.

- Shingletown, CA, USA

problem #11

Dec 142014

Ram 1500

  • 40,000 miles
The contact owns a 2004 Ford Ram 1500. The contact stated that while attempting to refuel, the fuel failed to properly dispense into the tank. The vehicle was taken to the dealer. The technician diagnosed that the fuel tank needed to be replaced. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was 40,000. Updated 3/13/15

- Barberton , OH, USA

problem #10

Dec 292014

Ram 1500 4WD 8-cyl

  • 114,000 miles
Just like everyone else who owns a Dodge, I went to fuel up the truck and it went all over the ground rather than in the tank...took it to the dealer...check valve bad...need new tank....never buy Dodge again..

- Levittown, PA, USA

problem #9

Nov 142014

Ram 1500 8-cyl

  • 82,530 miles
While filling tank fuel kicks back shutting off pump handle. Apparent orvr valve problem requiring entire fuel tank replacement. Seems to be fairly common problem on Dodge trucks.

- Belleville, IL, USA

problem #8

Sep 132007

Ram 1500 8-cyl

  • 24,000 miles
After filling gas tank full, engine dies when braking and turning a corner (losing steering) and coming to a stop. Starts back up fine, but stalls again on next low speed braking or turning a corner. Very similar to other accounts that I have read. I've had new plugs and O2 sensors costing mucho for zero result. When this occurs slowing down to make a slow turn, I have to throw it up to neutral to restart. Once I threw it in park going slowly, but it was dangerous to screech to a halt with a car behind me almost rear ended me. I've been told the same crap by dealers about this and I know they are playing dumb. The only remedy that I use for this is similar to others which is just don't fill it all the way up unless you are getting right out on the highway to run those speeds and not be stopping. I can't let others drive my truck unless I make sure that the tank is below three quarters of a tank. I can't believe that there's not a quick and dirty fix for this. Seems like you should disable emissions devices in the interest of safety.

- Waxahachie, TX, USA

problem #7

Jan 012013

Ram 1500

  • 103,000 miles
I have two issues which I believe are related. The anti rollover valve in the fuel tank is sticking preventing fuel from entering the tank properly and bubbling back up the filler tube. This happens whenever you attempt to put in fuel and has resulted in multiple fuel spills. The second issue is after a fill up the truck may stall 4-5 times while at idle at stop lights or even while rolling resulting in loss of power steering, power brakes and no advanced warning. Both issues have multiple occurrences. I repaired my fuel tank by adding an auxiliary anti-rollover valve and plumbing it into the existing evap connections. This after the dealer refused to warranty the tank even though some models have been recalled and this does have a bulletin published.

- Portage, IN, USA

problem #6

Mar 272013

Ram 1500 8-cyl

  • 80,000 miles
The contact owns a 2004 Dodge Ram 1500. The contact stated that while refueling, the shut-off valve engaged before the fuel tank was filled to capacity. The vehicle was taken to the dealer for diagnosis. The technician stated that the fuel tank would have to be replaced. The manufacturer was made aware of the failure. The vehicle was not repaired. The approximate failure mileage was 80,000.

- Ames, IA, USA

problem #5

Mar 202013

Ram 1500

  • 135,000 miles
Dodge 1500 stalls at slowing down. Same problem as reported in multiple postings here. Very dangerous situation.

- Cottage Grove, MN, USA

problem #4

Oct 262012

Ram 1500

  • 62,000 miles
While driving my 2004 Dodge Ram 1500 while turning at approx 5 miles per hour the car stalled out this has now happened on various occasions. There is no code and several repair shops don T have a clue what to fix and just want to start replacing parts.

- Deer Park, NY, USA

problem #3

Dec 292012

Ram 1500

  • 104,000 miles
Attempted to fill my gas tank. The fuel kept overflowing. I was only able to get $15 in gas as I had to slowly pump, wait for the overflow of gas to stop, then slowly attempt to add more gasoline. This took almost 15 minutes. The only reason I kept trying to get more gas in was the truck was on empty. In reviewing other similar complaints online, regarding this issue and with this vehicle, the symptoms are that of a faulty onboard refueling recovery valve. This problem creates many hazards with fuel and vapors not being contained.

- Minneapolis, MN, USA

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