Which parts fail
Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2005 Chrysler 300 owners, lightly cleaned up (personal details are redacted by NHTSA).
Strong fuel smell in cabin and outside of car when gas tank is full. Discovered gas in the cabin sitting on top of the fuel tank under the passenger-rear seat. Multiple posts in online forums confirm this is a known issue. Vehicle owner ordered a new o-ring to attempt repair. Area around fuel pump under driver's-rear seat was not affected. No warning lights, notices or performance issues. Only indication is strong gas fumes in car after filling up the gas tank (auto shutoff at pump, not topped off) which persists for several days. Problem seems minimized if gas tank is shorted 2-3 gallons from max capacity on fillup (about 14 gallons when car is close to empty per the gas gauge in dashboard.) Car was not inspected by dealer, insurance agent, police, independent service center, or anyone else other than owner.
Our 2005 Chrysler 300 stalls and will not restart for many minutes after we refuel it. Chrysler stated they have extended the warranty to a life time coverage if you are experiencing this issue you are able to get it covered under said warranty. We have contacted them and they state this one is not covered. How can we go about getting this covered. It obviously has the issue they have recalled and should be covered!! Thank you, Shannon Hainzlsperger
My 2005 Chrysler 300 has been having an issue with the fuel tank. When you get fuel in it then it won't stay started. It keeps stalling out repeatedly. It also stalls out randomly under 25mph. Both are dangerous as it may cause you to get T-boned leaving gas station as it repeatedly stalls. Also it stalled out on the freeway on-ramp under 25mph. This is also dangerous as you lose your steering at the same time. Someone could have been injured or killed. And Chrysler needs to take this more seriously than they did just with the 2005 300c. It's happening to more models of that year as well. Their offered remedy was telling me not to fuel it all the way up anymore past 3/4 of a tank. A dealership confirmed it needs a full fuel tank replacement and has had it since Memorial Day. They still have it currently. …
X53 extended warranty fuel tanks. Vehicle stalls while moving especially after refueling. Vehicle will stall at anytime especially after tank has been completely refueled, whether it be on side streets at slower speeds or on freeway at higher speeds. According to Fiat/Chrysler x53 extended warranty is only applicable to certain vehicles manufactured at specific manufacturing facilities, but does not include Chrysler 300 vehicles that were manufactured at other facilities other than ones specified. This particular vehicle was manufactured at another Chrysler facility that was not at one of the specified manufacturing facilities. Regardless of which facility this vehicle was manufactured, it still is experiencing the same issue. The vehicle stalls after fuel fill ups. This presents a safety hazard to vehicle occupants. …
Ii own a 2005 300c with 1001,500 miles. I had a problem with the car running out of gas when the gage was still showing gas in the tank wile driving in city streets, and once in highway. Luckily I was in the right lane. I complained to the dealer in two occasions of this occurrence. Finally the tank was replaced around 2014. After that, I went back to the dealer on several occasions complaining that after filling my tank with gas there was a strong smell of fuel. They keep telling me there was nothing wrong. Finally in October 2019. I took car back and was told there was a crack on the at top of fuel tank pump housing r/h, and gas was leaking from the attaching ring and the rubber hose and accumulating on some cavities at top of pump. The dealer quoted me about a thousand dollar for the job, and needed keep my car for 3 days. …
I was driving slowly, under 10 miles per hour, when it just up and died on me. Tried to restart, but would not. Let it sit for 5 minutes, pushed the gas pedal and held it half way down and vehicle started. But would not idle. Tried to hold pedal and put it in drive.to limp it home, but died when engaging drive. Long story short, it wont start or run unless you give it gas, will not idle in park, neutral, reverse or drive, and there have been hundreds of complaints for this. That being said, I'm assuming someone has to die in an accident, maybe several lives lost before you decide to take this seriously. You people do realize what happens when an engine stalls while driving yes? Loss of brakes for the most part, power steering, acceleration, the list goes on...now put someone behind the wheel that doesn't know how to react. …
Tl* the contact owns a 2005 Chrysler 300. The contact stated that while driving at 10 MPH, the vehicle stalled. The contact mentioned that the oil pressure warning light illuminated. The vehicle was taken to an independent mechanic were no error codes were detected during diagnostic testing. The contact stated that the vehicle was then taken to jim shorkey auto group dealer located at 13339 Lincoln hwy, north huntingdon, pa 15642, phone number: [phone], where the diagnoses was unknown. The contact stated that he found a x53 extended warranty (fuel tanks) for 2005-2006 Chrysler 300, that presented the same failure as his vehicle of engine stalling at low speeds. The manufacturer was notified and confirmed that the vehicle was not included due to the fact that the vehicle fuel tank was not the correct size and offered no further assistance. The failure mileage was approximately 45,000.
My Chrysler 300 touring began to stall any time I refueled in winter months. When I brought the car into the dealer they replaced the "vapor canister purge valve". That solved the problem temporarily. When the problem resurfaced I brought the car back to the same dealer and was told it now was a valve in the fuel tank and the entire fuel tank would need to be replaced. Cost of replacement was about $2500. The service tech said just don't fill up the tank to avoid the problem. I have been doing that in the winter ever since but last night after refueling it was fine until I was driving around traffic circle and the engine began to stall and I almost got rear ended by another car entering the traffic circle behind me. This seems to be a problem with a large number of these Chrysler vehicles. I have a hard time believing there hasn't been a recall on these vehicles for this issue!
Tl* the contact owns a 2005 Chrysler 300. The contact stated that there was an abnormal noise and a burning odor coming from the vehicle. Also, the vehicle failed to crank initially and would stall intermittently. The manufacturer indicated that the vehicle had been serviced on August 3, 2010 for a fuel system recall campaign in which both fuel pump modules were replaced. Sahara Chrysler Jeep Dodge Ram (5050 w sahara ave, las vegas, nv 89146, [phone]) diagnosed that both fuel pump modules needed to be replaced again. The contact felt that by replacing the same OEM fuel pump modules, the failure would recur. The dealer had not been authorized to service the vehicle. The manufacturer was notified of the failure and the contact was waiting on a response to determine their guidelines for the dealer's repair. The failure mileage was not available.
On sept. 28, 2015, the vehicle was being driven on a local road at approximately 45 MPH. The following lights became illuminated on the dashboard, ESP/bas and then the voltage or volt light came on and then the vehicle stalls out. The vehicle will restart . After getting the vehicle going again, it stalled out several more times including a major highway and crossing a bridge at 50 MPH. The vehicle was taken to the Chrysler dealer and was there for a week and a half with nothing being diagnosed as a problem with it stalling out. The following codes were stored in the computer. P1618, p1628 & p0441. The vehicle did stall out four times while driving to the dealer. There was a near miss collision as I was almost rear ended when making a right turn to merge into a traffic lane. The vehicle stalled out and I had to drift to the shoulder.
Fuel System complaints in other 300 years
Frequently asked questions
How common are fuel system problems on the 2005 Chrysler 300?
NHTSA has 81 complaints about the fuel & propulsion system of the 2005 Chrysler 300, 10% of the model year's 837 complaints. The component named most often is storage › tank assembly (4 mentions).
Is there a recall for 2005 Chrysler 300 fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for the 2005 Chrysler 300, though it has 7 recalls for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2005 Chrysler 300 fuel system problems start?
Half of the complaints with a recorded mileage happened before about 98,000 miles, and 6% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 1 fire and 0 injuries to fuel & propulsion system problems on this model year. If you notice symptoms, have the car checked before driving further.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.