Chrysler Repair/stalling after refueling
Dan the Man wrote at 2009-01-23 19:02:30
I have the exact same problem. My Wife and I have both experienced this. would it be possible there is debris in the fuel tank and when you fill it up it stirs it up and it clogs the fuel filter briefly? It is a very bizarre condition.
J.C. wrote at 2009-02-18 17:03:58
I have a 2005 T/C and have this same problem. I am with you Dan the man, that I think I got a bad tank of gas and I am stirring up water/dirt. I have not troubleshot this problem yet, however I noticed that it doesn't do it if I have half a tank or more of gas. I am leaning toward the water in the bottom of the tank answer. Another mechanic told me to use "Heet" additive to fix the problem. Other than that, wait until the tank nears empty and siphon out the rest of the gas, and change the fuel filter. Hope this helps or maybe someone can help me with the right answer. thanks J.C
Neil wrote at 2009-08-04 19:56:36
Our 2004 T&C has just recently begun to stall after fillup. It never did this before, but now we've hit 100,000 miles, so maybe age has something to do with it. I suspect a sensor malfunction. No "hard-code" faults have been triggered (check engine light), but maybe a soft-code might be stored in the computer. My next steps are to fill up when only 1/2 empty, and also do a diagnostic scan.
Boston Joe wrote at 2009-09-13 13:33:15
My wife 2004 Town & Country (3.8V6) is also experiencing intermittent stalling after filling up. Then will be fine after driving 20+ miles.
Mike wrote at 2009-12-02 02:42:25
We have a 2005 Town and Country which is having the same problem. At about the same time, the automatic door locks started to intermittently stop working which the dealership would correct by resetting/clearing an error code. Note sure if the two issues are connected in any way.
Mike wrote at 2009-12-02 02:48:36
Check out this link:http://www.ricksfreeautorepairadvice.com/diagnostics/by-symptom/engine-stalls-se
Vin-J wrote at 2010-01-12 16:30:30
Engine stalls several times right after filling tank with gas, Chrysler Minivan
Shops are reporting a problem with the gas tank on Dodge Caravan, Grand Caravan, Plymouth Voyager, and Town and Country vans. Shortly after refueling, drivers experience engine stalling. The stalling may repeat several times.
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. Itís 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. Thatís 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.
big-H wrote at 2010-07-29 02:12:50
My question is, how bad is this for the car? I.e. will this damage any other parts and is it worth repairing if it only occurs sometimes when you fuel up...
John B wrote at 2010-11-18 02:26:02
We have 2005 Town & Country and have been having similar trouble with our vehicle. We purchased our T&C in Corpus Christi, in May of 2005. Our vehicle is a Limited Edition. Our issues started last fall when the vehicle had roughly 39,000 miles on it. As I read Roland's answer this evening we compared our experience. Our vehicle stalls have occurred after fill ups, typically we allow the pump to stop automatically. We have had stalls after filling up after driving 5-10 minutes and we have had stalls after driving all day. During the last stall, the car took several turns of the key to start the engine back up. Like your experience, the vehicle does not stall a second time.
We have called our local Chrysler dealer and they claim to not have heard of this problem. I don't this is an isolated issue, but rather design flaw.
Mary wrote at 2010-12-04 23:47:27
We have a 2005 T & C that does the same thing, and I don't top it off, just stop filling it when the pump clicks off. Sounds like a design flaw to me, and one that leads to dangerous situations when it stalls in the middle of the road. One of the service guys at Chrysler said he had heard of this, but his only suggestion was to replace the gas tank. It's a $700 repair, which I don't want to do.
SLL wrote at 2011-02-14 03:39:48
So, is this something Dodge is, or should be, announcing a recall on? I am having the same problem w/ my 2007 Dodge Caravan.... it stalls right after refueling.
mjmsail wrote at 2011-02-21 18:37:33
This does sound like a design flaw. I bought a 2004 T&C Limited in November of 2009 with 55,000 miles on it. At about 75,000 miles it started to stall right after filling up. It is a dangerous situation especially if it stalls in the middle of an intersection or on railroad tracks. Has anyone contacted Chrysler Customner Service?
Peter wrote at 2011-05-19 04:48:19
I also have a 2004 Town and Country which I bought new. It started stalling after refueling about six months ago. The dealer is planning to replace the gas tank, some valve, and fuel injection. I just hope it works! I'll report here again if it does.
the don wrote at 2011-12-15 01:33:11
samething 2004 dodge caravan stalls after refueling. then re-starts. Of course the dealer has heard of this but if you expect a recall forget it. just like the headlights that get dull so u can't see as far at night. an obvious safety problem and never a recall on any model or make.
Candice wrote at 2012-08-24 20:15:17
I just bought a 2004 T & C on Monday. On Wednesday we had it towed back to CarMax where we got it. Same problems as described. They weren't able to find anything wrong with it. SUPER FRUSTRATING!!!!!!! I called Chrysler to see if there was a recall, etc. They say there is no record of any other compliants for this. He said if more complaints come in then they may be able to do something about it. So call 800-247-9753 to complain and let's see if we can get this taken care of!! I am so mad right now I don't know what to do!!!!!!!!
Tim wrote at 2012-10-01 20:00:49
I too am having the 2004 Grand Caravan stall problem. 145k miles on it and it stalls whenever I fill it full of gas. Chrysler said that they are UNAWARE of the problem even though another person previously complained and posted the number here 800-247-9753. You need to call them so that they might replace the gas tanks. If you don't call, nothing happens!
mark2870 wrote at 2012-12-16 20:43:33
My wife has a 2006 T&C Limited with a 3.8L engine with the exact problem reported here. It has 56,500 miles on it. The problem has been present to some degree for about a year, but it's gotten bad enough that I will have to do something about it. As others have said, within one to three minutes after refueling, the engine hesitates on acceleration, sputters, lurches, and dies. Sometimes it won't restart immediately. After about two minutes of waiting, it starts just fine and all is well until the next fill-up. As a temporary fix until I can have the fuel tank replaced, I will try filling the tank to no more than about 2/3s, to see if that helps. Thanks for the information from the experts and non-experts alike.
Cawashbu wrote at 2013-01-04 20:49:26
We have had this same issue with our 2004 Dodge Caravan. With topping the fuel off the engine sputters and dies after we leave the filling station. Pumping the gas peddle sometimes gets us through it. It started around 107,000 miles and has become worse with time. Our mechanic diagnosed a throttle body issue, cleaned it and we were trouble free for about a month. The surging and sputtering came back. We plan to keep the van, now at 130,000 miles for another three years and will look into replacing the fuel tank, though this expensive fix isn't preferred. I am interested what information that Dodge and Chrysler provided others?
Bo wrote at 2013-01-16 06:12:20
just to confirm on this board that this issue started with my 2005 t/c around 120k miles, wasnt sure what the issue was but now after reading/finding this thread, i can confirm it happens to me.
anyone have any luck with getting the tank replaced free of charge
Dave M wrote at 2013-03-17 03:54:17
I have a 2007 T&C with 60K miles that started stalling after filling up about 6 months ago. Like others have stated, the problem goes away after a short time until the tank is refilled again. The theory about the defective liquid separator valve in the tank makes sense. I've been trying to find another recommended cure besides replacing the tank, but haven't found any other credible answers yet. I'm having a hard time convincing myself to spend the money to replace the tank, then find out that a $10 part was the real problem. I would really like to hear from somebody who has replaced the tank to find out if it really cured the stalling problem.
janet wrote at 2013-03-20 20:57:06
I have a 2007 Dodge grand caravan and it has the EXACT same problem! it's been going on for about a month now... How long can I drive like this, am I causing more damage? It stalled on a busy road yesterday... so frustrating!!
janet wrote at 2013-03-20 21:09:27
also... does anyone else have their check engine light on with this problem?? or do I have another issues causing this light to be one?
T&C Owner wrote at 2013-03-26 17:42:57
I have a 2004 Chrysler Town & Country with 118,000 miles. I have also just started to experience the stuttering and hesitating after a full tank gas fill up. It occurs right after I leave the gas station. Today was the first time it DID actually stall out and the check engine light went on. I was petrified as I was in the middle of an intersection! Thankfully, I just put it in park and was able to restart the engine, but I Googled as soon as I got home and found this page. I called the number on this thread (800-247-9753) and spoke to Chrysler Customer Care. The representative said that she had no record of this problem. I began to read her all of the vehicles with problems here and she explained her records are for MY CAR ONLY! I said, "Then how will Chrysler know that all of these vehicles are having problems?" The rep told me I have to take the car to a Chrysler dealer and pay for a full diagnostic work up. Any issues or repairs will be my responsibility as the car is no longer under warranty. I just thank God I wasn't on the highway or on the railroad tracks and couldn't get it started again. Not happy!
Empie wrote at 2013-03-30 02:00:04
I have an 04 T&C and same issues!!! Car always dies out after filling up, let the gas pump click never top off! Car has died on me in the middle of busy intersections with kids in the car! I am deathly afraid to fill up. Can't go anywhere long distance if there is no gas station nearby. Took it to the dealership and they said the idle control valve was stuck and this should fix the problem. Lo and behold, that didn't happen and the same issue a few days later. Needless to say the dealership won't return my calls and emails and I'm ready to junk the POS car! It's been in the shop 15 times since September and I will never buy another Chrysler!! Btw anyone else having issues at low fuel levels too? Mine runs horrible at a 1/4 of a tank and doesn't even want to move!
Roland wrote at 2013-04-03 17:21:36
Chrysler issued a service bulletin about this problem in '09 which might help in diagnosing what is wrong. You can check it out at:
Cjb atlanta wrote at 2013-05-16 01:06:33
My 2005 t&c got the problem of stalling after filling up with gas.
It is very dangerous as the steering locks when the engine cuts out.
I had to replace the fuel tank as well as another part adjacent to it.
Chrysler needs to recall these cars!!
BCJones wrote at 2013-08-27 21:36:58
I have a 2005 T&C with the stall-after-filling problem. I learned quite awhile ago that the valve on the gas tank, which cannot be replaced without replacing the whole tank (part costs about $370 online, then there's labor), was the cause of the problem. Normally, gas vapors collect in a canister filled with charcoal particles that is mounted below the floorboard, about where the driver's seat is. A pipe connects this vapor/liquid separator valve on the gas tank to the charcoal canister. The van's computer "purges" the vapors from this canister after a set time and when the engine is sufficiently warmed up. When the vapor liquid separator valve on the gas tank fails, it allows raw gas to enter the canister, and then when the purge valve opens (located in the right, front section of the engine compartment), raw gas is sucked out of the canister and into the intake manifold, thereby enriching the mixture so much that the van either stalls or almost stalls. The van's computer never recognizes the problem, so there is never an error code set. So the only option is to replace the gas tank (not a job for the inexperienced home mechanic!!). The charcoal canister has no doubt been contaminated with a lot of raw gas, so it may need to be replaced as well, but maybe not. I'm not sure how one would know for sure. As a side note, I started getting a P0441 error code from the van's computer. This was caused by the failure of my NVLD pump (natural vacuum leak detector), a fairly inexpensive part. I opened it up and found quite a bit of liquid in it, and I can only assume it had entered from the canister, to which it is directly connected. The liquid had contaminated a micro switch inside causing its failure, which is what caused the error code. I replaced the NVLD and the error code has not returned, but my van still stalls if I fill it all the way up. Like others here, I believe Chrysler should issue a recall and replace the tanks. Perhaps when someone dies due to stalling in the middle of an intersection and then initiates legal action, Chrysler will take action. I wish corporations had souls and moral consciousness, but they don't. They only understand the power of money.
Vic wrote at 2013-08-30 21:42:37
I also have this problem. I recently purchased a used 2004 chrysler T/C limited. The van stalls on me while leaving the gas station after refueling. I agree that this is very dangerous and Chrysler/Dodge should look into some type of repair kit for these vehicles. I will be pushing the issue on this. From my experience with troubled vehicles over the years... The manufactures and dealerships are not willing to help unless they are forced to help. Anyone with this problem should write there local legislators and demand action. This was a slow but very affective process for me in the past.
Mommobile4 wrote at 2014-01-02 15:31:14
Just called the number to Chrysler Customer service and they still act like no one has complained about this. I have a 2006 Town & Country with 130,000 miles on it.. I will go back to Toyota or have no choice to repair it since this is such an "isolated" issue! Wow!
Charles Woodard wrote at 2014-04-15 00:49:14
I have a 2007 T&C minivan with 102685 miles on the odometer. One month ago I started experiencing the stalling after filling up. At first I suspected bad fuel, but it kept happening wherever I bought gas. Then the engine light came on and I took it to the Chrysler dealership.They "checked dtc's found P0441 nvid pump internal failure" and replaced part # 4891427AB, Detector Natural Vac for $167.70 parts and labor. After that two more fill-ups and two more stalls. Engine light back on. took to dealership again and was told the EGR valve was bad and I would have to pay another $300.00. I talked to the Service
Mgr and he said replacing the EGR valve would clear the engine light but might not solve the problem. As of now the vehicle is still in the shop being evaluated. After I found this website I called the Service Mgr and told him about it and he replied that they had access to this information. That tells me they know about this problem and don't want to admit it. I will get in touch with NHTSA next.
jose wrote at 2014-04-15 16:51:49
My 2004 Town & Country (3.3 V 6) is also experiencing intermittent stalling after filling up. Then will be fine after driving 5 miles.We all should complaint to www-odi.nhtsa.dot.gov
Brian wrote at 2014-07-03 00:33:12
Add me to the list of people who are having this issue. Our 2007 Grand Caravan SXT has about 44,000 miles on it and the stalling after refueling began on our vehicle about a month ago. I thought I got a bad tank of gas, but today my wife (with kids in car) stalled on the highway. The danger was that she was on a turn and the steering wheel became impossible for her to turn it. This IS a major safety issue, and my hope is that Chrysler makes good on a defective part. (I see they did that after a gov't investigation of a similar nature for other cars...http://www.carcomplaints.com/news/2014/investigation-closed-chrysler-stalling-en
EVERYONE- PLEASE go to NHTSA and select "file a complaint" and fill that info out! The more people who document this, the more Dodge/Chrysler will take notice and take action. This is a SAFETY ISSUE and eventually there will be a fatality!!
Steve wrote at 2014-07-28 20:35:52
Add me to the long list of people with this problem. 2004 T&C with 80,000 miles. I assumed (wrongly) that there was debris in the tank causing pump suction problems. Removed the tank, replaced the fuel pump, cleaned the tank (it was already sparkling clean inside - surprise!). The fuel pump suction strainer was deteriorated and falling off, so I assumed that was the problem.
Then...at the first fill-up. It hesitated and nearly stalled again. I was researching EGR valve failures when I happened upon a whole bunch of reports of stalling after fill-up.
The Chrysler help line lady said that there was one fuel tank issue that is covered under extended warranty, but no recalls.
Doug wrote at 2014-09-08 15:26:35
Yup, add me to the list. I have a 2003 Dodge caravan with 224,000 miles on it and have experienced this same problem. Took it to the dealer several times and they could find nothing wrong but did note the canister had raw gas in it. I bought this car new and have dealt with this problem by not completely filling up the tank. My stalling only occurs within about 100 feet from the gas pump. Car restarts immediately with no problem but have had some close calls while pulling out of a station when car stalls and steering and brakes go.
Amy wrote at 2014-10-11 05:16:54
My 2007 Jeep Patriot has 99,000 miles on it and has experienced this problem three times. After filling up with gas, when the car slows to almost idling, the oil light comes on, the wheel locks and you can't turn it, and then the car stalls. It will restart right away, but then as soon as it should idle, the rpms drop to zero and it stalls again. It will then restart and run fine.
Steve L. wrote at 2014-12-14 22:03:01
I have a 2005 Town & Country with about 87,000 miles on it that stalls after fill up. The first time it happened to my wife with 4 kids on board half-way thru a 700 mile trip to see Grandpa & Grandma. I do as much vehicle maintenance myself as I can, but I was completely helpless not knowing if they were going to get stranded so far from home. It stalls now after each complete fill up and restarts after cranking the engine for 3 - 5 seconds, but meanwhile we're dead in the water hoping we don't get into an accident.
wayne wrote at 2014-12-20 01:43:49
i also have this problem ,my car stalled after a fillup and i almost got killed on a highway
GC wrote at 2014-12-22 01:15:08
Same exact problem with our 2006 Dodge Grand Caravan 3.8L with ~78000 miles. Last 2 times after fill up, pulling into traffic out of the station. Very dangerous.
Wendy wrote at 2014-12-30 15:42:05
I also have had this issue for at least 2 years. I made a complaint with NHTSB and hope others do the same. My van needs to be filled up but I dread it!
mxmikie wrote at 2014-12-31 03:25:53
mxmikie wrote at 2014-12-31 03:28:58
Mike Carey wrote at 2015-01-01 19:08:06
January 2014 we purchased a 2006 dodge caravan with 16,000 miles from a dealer in a neighboring state. We have experienced multiple engine stalls all of which occurred after refueling.
aslwalker wrote at 2015-01-14 02:53:27
I am so happy to see that there are so many others that have been struggling with this very dangerous issue. I bought my 2006 Chrysler Town and Country with 97k miles in February 2014 from a local dealer. The first time I filled the gas tank and about 75% of the times following, it has stalled as so many have described here. Often, the car stalls in an intersection.
The dealership mechanics and shop have given me the runaround as well, claiming that they need to be able to reproduce the problem in the shop and claim that they do not know what the problem could be. I asked some other mechanics about the issue and they were able to tell me that it's probably the emissions valve, without even seeing the car! It's very clear that all these folks are obfuscating to save their bottom lines. I shouldn't be surprised by now, that these companies do not care about our safety, just the almighty dollar.
We need to find a way to make these safety concerns known and force Chrysler to issue a recall.
Jim wrote at 2015-01-17 13:30:55
Had the same problem it only died after a fill up and most the time just once turned out to be the AGR valve no problem since re-placment cost right at 100.00
Deb wrote at 2015-01-22 00:55:58
I had the same problem; figured we just got a bad tank of gas. Added stabilizer. Stalled 3 times in last month, all after refueling. Took it to our mechanic, who replaced the Crankshaft Position Sensor, as there was a known issue with that. It stalled after the next time we got gas.
I just filed a complaint with NTSB, thanks to you folks posting this issue.
I wonder how many people need to be killed in an accident due to stalling before Chrysler/Dodge takes ownership of their defect and corrects it?
Meanwhile, they should never have put computers on cars or motorcycles to begin with - it was a deliberate error, to stop the 'Saturday mechanic' from doing their own repairs. JMHO
Sandy wrote at 2015-02-10 02:12:52
I thought I have been going crazy telling people how my 2007 Dodge Caravan is stalling after getting gas. Apparently I am not crazy it's Chrysler/Dodge putting mine and my families life in danger. Thank you for sharing the complaint site as I will be more than happy to file a complaint as this is totally unacceptable. Please if anyone hasn't filed a complaint do it! Or if you hear of someone having the same issues please have them file one. This will not become a recall if we do not file. Our lives as well as our loved ones are depending on this.
joshua wrote at 2015-02-15 05:38:02
Same problems here. Happened three times...first twi times it just sputtered and I thought my transmission was going out or I had a clogged fuel filter. The third time I was completely shocked when my car shut off while turning on the highway...locked out my steering wheel and put me into the opposing lane. Fortunately we were on a Country road, but we had our family of five in tow on a family trip. I'm irate to see/heAR that others have had the same problem. Just filed my complaint as others have suggested and will NEVER buy a Chrysler again.
John wrote at 2015-02-17 07:36:40
Same problem with 2006 Town & Country, filed the complaint.
kristine wrote at 2015-02-23 04:28:06
Yes same problem with our 2007 T & C for several years now. I have to disagree with replacement of gas tank as a fix. My tank was replaced 3 years ago After a puncture. And We currently have this problem of stalling after fill up.
Don R wrote at 2015-03-02 23:08:55
I had this problem on the last two Dodge Caravans, the 2005 was never figured out, and the 2004 I just got with 165,000 miles started to act like it was going to stall just after I filled up today. My question is, if I don't fill the tank all the way, like maybe 3/4 full, does thus seem to help? I HAVE A 2006 T&C with 293,000, I bought new,never had this problem. An 05 T&C before that with no stalling.
Rob M wrote at 2015-03-03 12:13:40
I'm experiencing the same problem for over a year with my 2006 Dodge Grand Caravan. It started at about 90,000 miles and now has about 95,000. The stalling happens so reliably during the first drive after every fill-up. I finally decided to look into it and do something about it. I called Dodge/Chrysler yesterday and of course all they would say is that it is not on their recall list but I will be notified if it is recalled. They would not say/admit if there are other complaints, which we all know there are. So now I have to decide whether to bring it to a Dodge dealer and pay through-the-roof price to have the gas tank replaced or go to my local mechanic.
MD wrote at 2015-03-07 23:49:06
My 2007 Chrysler T&C is consisttenly stalling every fill--up. I can volunteer it to be a test vehicle for a lawyer wanting to take on Chrysler. I took care of this vehicle, all maintenance records kept at a local shop. It is frustrating to know that so many already had called Chrysler and yet no recognition of the issue.
What's the next step?
Destiny wrote at 2015-03-09 14:57:56
I am so glad I stumbled on this thread! I've been experiencing the same thing with my 2007 Jeep Patriot Limited! The first time this happened was on Christmas Eve while traveling a long distance home after filling up with gas (imagine my fear!). I tried ISO HEET because I thought I got bad gas, which seemed to help for a few fill ups. As of now every single time I fill up, the car will stall, oil light come on, and the steering and ABS lock up. After turning the car off and restarting, it'll usually jump a couple times while accelerating, then it's okay until I'm idling for a long period of time. Chrysler NEEDS to admit faulty design and recall! I will never buy another one of their cars again because of this!
MD wrote at 2015-03-11 02:46:41
Update - I have submitted a complaint on the NHtSA website. After a day, I got a reply back with the complaint number. This is encouraging sign. This said, I would suggest everyone on this board to submit a complaint as well.
Chuck wrote at 2015-03-22 15:52:55
I have a 2007 Jeep Patriot and experience this staling after refueling as well. Stalling in intersections and on the highway even. This is extremely dangerous. I am filling a complaint as well.
Les wrote at 2015-04-01 14:44:25
I have a 2007 Jeep Patriot that is experiencing the same thing. I will be filing a complaint too.
Clara wrote at 2015-04-04 13:30:59
Vin-J, thanks for the your info ... it is 100% accurate and exactly what my dealership told me I need to do (replace gas tank and canister). When I found your answer, it wasn't what I wanted to hear but is very helpful and it backs up what the dealership told me. I've got a 2005 Dodge Grand Caravan, bought from a used car place four months ago -- the problem presented immediately. The tank and canister replacement for parts and labor is somewhere over $2000 (not sure of the exact amount as it sort of put me in shock since I'd just had many other repairs also done. Anyway, thanks for providing your information, as it clearly explains the problem, its cause, and its only solution.
Hemiwagonrt wrote at 2015-04-08 14:15:52
Hi. Not a minivan owner, but an LX owner (300, Charger, Magnum) and we experienced the exact same stalling conditions after refueling. The problem turned out to be poorly designed gas tanks and Chrysler agreed to provide a lifetime warranty on 2005-2006 cars with 19 gallon tanks. Here is a link to a discussion about the stalling on lxforums.com:http://www.lxforums.com/board/showthread.php/335051-Stalling-after-re-fuel-is-fi
I saw today's press release that NHTSA will not investigate your issue. Perhaps you guys can pursue other legal actions and use the LX platform to bolster your claims. Good luck.
stress wrote at 2015-04-09 14:37:40
Have anyone tried to change the purge valve and charcoal canister? Probably might help
MyTwoCents wrote at 2015-05-22 02:01:24
L1 ASE Tech
Vehicle: 2005 Caravan 3.3L
COMPLAINT: Vehicle dies (stalling after fill up), and has been occurring for the last couple of years.
TEST DRIVE: Straight to the station for a fill up, pump shut off automatically, no top off. Upon leaving the pump the engine started to stumble (300-500 yards) and eventually cut out. After two failed attempts of immediately restarting, key off 2-5 minutes, vehicle started and drove back to the shop (1.0 mile)
DIAGNOSTIC: Having plugged in my Snap-On Solus Edge scan tool before leaving the shop, I was able to verify purge valve duty cycle/operation on the trip to the station and on the return trip via recorded data. When leaving the gas station the purge valve was commanded ON 28% duty cycle via PCM, upon which the vehicle then stalled completely (no Malfunction Indicator Light, no codes). After being a tech for the last 14, and having dealership friends that have seen this before the first inspection point was the EVAP purge valve (passenger side of engine compartment, next to radiator). After disconnecting the two rubber lines and electrical connector (you must slide red lock tab to unlock), I tapped the purge valve (inlet & outlet side down) on my stainless steel work bench on to find 3-4 droplets of raw fuel. As stated before in the beginning of this forum, raw fuel should NOT be in a vapor line.
SOLUTION: Replaced fuel tank assembly, purge valve, and purged the charcoal canister of any raw fuel that may have settled. Had the customer drive the vehicle until a half tank remained at which point the customer returned to shop for another fill up. With scan tool plugged in and data recording, a full tank (pump shut off automatic), absolutely no stalling, spitting, or sputtering. Drove vehicle for another 40 miles (highway/city) without problem.
FOLLOW UP: It's been 2 months since repair was completed, customer has filled tank multiple times since without future problems.
-I'm not saying this is the fix for every vehicle experiencing this issue, but if you become familiar with the location of this valve and practice removing at home, and if possible to check after a fill up stall (open parking lot), it might confirm if this repair applies to your vehicle.-
Chrysler 300C wrote at 2015-05-28 00:50:51
My 2006 Chrysler 300 C has been doing this for over 2 1/2 years after a fill up at a low end gas station while traveling. I thought it was bad gas and thought it would work itself out, but ... no. It stalls worse if I use more than 1/2 a tank before refilling, but it always stalls at least twice in the 1/4 mile from the station to my house. I have gotten proficient at dealing with a deadweight vehicle, but it is hazardous when traveling and I have to get on the freeway right after refilling. The next day it runs fine. I will take MyTwoCents suggestion to my car guys and see if it might work on my model.
Chrysler 300C wrote at 2015-05-28 01:41:26
I was able to get this fixed for free at the Chrysler dealer. Contact chrysler online and chat to one of their reps. You take the car to the dealer and they ID based on VIN and fix it.
Tw wrote at 2016-01-30 01:47:40
We received a letter from Chrysler today regarding extending the warranty on the gas tank for 15 years. Ironically, we just had our tank replaced on Tuesday. I hope they cover that bill. This is for the problem listed above in many of the postings.
Jaycool wrote at 2016-01-31 04:37:39
Chrysler just sent me a letter acknowledging that this is a defect and they will fix for my 2004 Town and Country. Please contact your dealer for details.
Cathy wrote at 2016-02-09 18:06:24
I brought my 2004 Dodge Mini Van anniversary edition in to get this fixed. My car stalled pretty well every time I did a fill-up. Beware that they will tell you that they will need to do a diagnostic test fist at a cost of $100 + tax to determine whether you need this job done or not. I explained to the dealership service department all the problems we had had since we bought it brand new in 2004. No exceptions pay or we will not do the work. Dodge Chrysler has lost a customer. Next car will be a Ford.
Cazman wrote at 2016-02-10 15:48:11
Also recieved letter extending warranty on gas tank for 15 years and unlimited mileage. Have brought car to dealer and they are changing gas tank as well as evaporate canister under extended warranty. Vehicle is a 2004 Town and Country with 115,000 miles.
Dodge wrote at 2016-02-20 16:52:20
same problem with 2004 caravan. I won't be surprised if someone got killed by this problem.
jjoan wrote at 2016-04-25 22:20:14
I recently had my 2004 dodge mini van repaired by dodge and in the process they put on the old fuel pump and old retainer. As soon as i filled the tank up and drove I smelled gas. Called them they said new tank will smell not to worry. I drove for another 4 days then needec to fill again. Same thing happened with the smell being worse. Had it looked at by another person they said get kids and carseats out before it blows up. The old parts that the dealer put back on did not seal cause of rust and raw fuel was pouring on hot exhaust pipe. Neither Chrysler or the dealer will pay to have it fixed, THEY SAID NEEDS NEW FUEL PUMP. Im retirec and cant afford can someone help
ykul wrote at 2016-05-03 23:46:42
Would love to know Cazman how you received your extended warranty on the T&C. Dealer says caravans were not covered, and I called Chrysler Customer Assistance and they tell me I'm not covered either. My only choice at this point is to fix it for $1015 at the local Dodge dealer, or scrap the car and switch to (probably) Ford. So they won't extend the warranty for me, and they're going to lose my future car purchases. Poor business decision if you ask me. Well, it was a nice marriage while it lasted! 2005 Dodge Grand Caravan SXT, 3.8L
Loyal Chrysler/Dodge Owner (Until Now) wrote at 2016-06-09 18:10:46
Our 2004 Town and Country has been doing this for several years now. When I contacted Chrysler customer service, I was informed that our vehicle was not on their list and not eligible for the free replacement.
I am curious as to whether anyone knows what criteria was used to compile this list. Perhaps it should be modified.
SuperBengal wrote at 2016-08-16 15:27:21
I have a 2005 T&C LX with exact same problem. I just called customer service and they said basicall, tough, your factory warranty expired. When I started telling her that they should stand behind the car and the parts especially if they put in a flawed part she hung up on me. And I was very polite. this is crap. I would like to look into a class action lawsuit. I can't afford to replace all that stuff.