Which parts fail
Components named in complaints (engine, cooling system, oil leaks, timing chain, exhaust).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2004 Chrysler Town and Country owners, lightly cleaned up (personal details are redacted by NHTSA).
Tl* the contact owns a 2004 Chrysler Town and Country. While driving various speeds, the steering wheel seized and became difficult to maneuver left or right. The ABS and engine warning indicators illuminated. The contact also stated that the vehicle failed to accelerate while depressing the accelerator pedal. In addition, the contact stated that the vehicle would overheat. The vehicle was taken to boyd Chrysler Jeep of south hill (200 w danville st, south hill, va 23970), but was not diagnosed or repaired due to the diagnostic and repair fees. The manufacturer was not contacted. The approximate failure mileage was 134,000. Consumer stated in the last few months the van has had problems. Smoke comes out of the engine and it has holes in the gas tank and by that it doesn't pass the inspection. Updated 7/26/18
After filling up with fuel, the car was started, and driven out of the gas station, but less than 50 feet out onto the road, the car lost power then regained power then lost it cycling rapidly through this where RPM would come up to idle speed than drop to near zero up and down. No ability to move out of traffic, etc., eventually completely stalled. The car started hard, but restarted and I could drive out of harms way. The car drove for about 2 blocks and acted up again for a few moments and then performed fine. This problem also occurred for another driver in the family about 2 weeks (4 fuel fills) earlier.
For the past five years (since 2009), my 2004 Chrysler Town & Country van wants to die soon after every time that is filled with gas (no matter the octane type). The problem most typically resolves itself after 5 minutes or so, but in the interim there have been numerous close calls as the van loses function with the power trying to die. I have ended up learning to drive with the car in neutral and coast while revving the van. Or better yet at a stop light race the engine with the car in neutral (I see nothing bad that can happen with this solution!!). For the most part the car is used only when needed anymore as we are terrified of filling the car up. We are very lucky to be able to drive it part time but some people aren't so fortunate and this is a car that drives many families. …
My van completely shut down after I filled the tank with gas. I didn't know what happend but I had no power to steer to the side of the road and had to turn off the engine and try to restart it several times before it started again. I have had this problem every time I fill the tank, from any level of gas. If I can leave the gas station and travel to .7 miles with constant pressure on the gas pedal, it sometimes won't die. If I have to brake, the engine completely chokes out. I have taken it back to the service department and they said they couldn't fix it because they needed to be able to fill it to see it happen and they weren't going to do that. Finally after a year of this problem and a multitude of others, I called Chrysler USA and all of the sudden, I had a manager at the service department volunteer to ride with me to see it happen. …
The 2004 Chrysler Town and Country check engine light came on and the engine was running rough, especially in idle. The odometer reading was 37,500, the vehicle was 3.5 years. Old, and it has a 3.8 liter engine. A Chrysler dealer ran a diagnostic check and determined that new spark plugs and wires were needed. Also, some computer codes May need to be reset. Cost would be $350. I bought the parts and installed them myself. I replaced many spark plugs in the old days and these were the worst looking plugs I have ever seen. The tips of the electrodes were severely rounded off on all 6 plugs. I owned Chrysler/Plymouth minivans since 1984 and only remember replacing spark plugs once, and probably @ a high mileage. Champion warrants their platinum plugs for 5 years. Chrysler's maintenance schedule says to replace spark plugs and wires @ "100,000 miles". …
Dt*: the contact stated while driving 20 MPH or less, the check engine light illuminated followed by hesitation of the engine. The vehicle was inspected by a dealer. A diagnostic test was performed and the dealer determined a spark plug needed to be replaced. Afterwards, the problem returned, and the vehicle was taken to another dealer for replacement of all spark plugs, spark plug boots, and the ignition. The problem persisted, and the vehicle was taken for an additional diagnostic test and it was determined there was a faulty EGR valve. Other people to whom the contact spoke to had similar problems with the Chrysler 3.3 litre engine. The contact has to pay $100.00 deductible every time that vehicle is taken to the dealer. The contact feels there should be a recall. Updated on 06/01/2006.
Tl* the contact owns a 2004 Chrysler Town and Country. The contact was driving 25 MPH when the check engine warning light illuminated. The contact then noticed that the temperature gauge was indicating that the vehicle was overheating. The vehicle was taken to an independent mechanic where it was advised to the contact that the engine oil had become too hot and was clogging the catalytic converter. The manufacturer was contacted and made aware of the failure but offered no assistance to the contact. The vehicle was not repaired. The failure mileage was 90,000 and the current mileage was 105,000.
After refilling the tank at any gas station and restarting the vehicle, it runs rough and stalls. The stall can occur anytime from right after the engine restart or up to 5 minutes after restart. The car has stalled in the gas station on numerous occasions since first noticed in dec 2010 and several times on the road in traffic. A web search indicated that there was an apparent issue with the vehicles fuel tank and "purge" valve. I found dozens & dozens of complaints. This seems to fit into a safety recall category. Please investigate
Engine stalls each time the fuel tank is filled. This happens only once per fill up and only after leaving the fuel station and entering the adjacent roadway. This is a dangerous condition as there is no warning and no power to steer and pull off the road to re-start. Re-starting can take a while to achieve in traffic. This is a dangerous defect apparently requiring replacement of the entire fuel tank? Why is Chrysler not required to recall these vehicles as it is a very common and dangerous failure?
Every time when fill up the gas tank the engine will stalled (but you can start up ) will run rough for 4 to 5 miles after that engine will back to normal condition, I have known a lot people have a same problem with there types of vehicles, this does sound like a design flaw. 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. Chrysler should recall there types of vehicle.
Engine complaints in other Town and Country years
Frequently asked questions
How common are engine problems on the 2004 Chrysler Town and Country?
NHTSA has 25 complaints about the engine & cooling of the 2004 Chrysler Town and Country, 15% of the model year's 167 complaints. The component named most often is engine (2 mentions).
Is there a recall for 2004 Chrysler Town and Country engine problems?
No. NHTSA lists no engine & cooling recall for the 2004 Chrysler Town and Country, though it has 1 recall 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 2004 Chrysler Town and Country engine problems start?
Half of the complaints with a recorded mileage happened before about 71,000 miles, and 18% before 25,000 miles.
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.