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 2004 Chrysler Town and Country owners, lightly cleaned up (personal details are redacted by NHTSA).
Right after vehicle passed the 100,000 mile mark around August of 2013 the van would start to chug and stall as soon as you filled up the gas tank. First time this happened was attempting to merge into traffic and was almost hit since lost steering and could not control the vehicle. Had wife and 3 kids in the van. Issue still happening on every fill up. Usually once you restart the vehicle it drives normal. Researched and found that this stalling issue is very common with the 2004 Town & Country. Apparently the issue stems from the filter on top of the gas tank which Chrysler is aware of, but no recall. Have tried to not fill completely up which sometimes helps, but stalling can still happen. Many similar complaints of this issue with potential accidents so a little surprised this has not been addressed by Chrysler. …
Purchased van used from a Toyota dealership in May of 2010. Reported within days to dealership that van had a stutter when at idle. They gave it a tune up but it did not resolve the issue. Warranty purchased with van did not cover the fuel system. Stuttering continued and became worse as the years went by. Van began to die when idling, especially if turning left which put us in danger a number of times. Also, we smelled fuel. We replaced the tank in 2013. However, our mechanic informed us at the time that it had a design flaw and the same issues would occur in a matter of time. Tank was fine for two years. Within a month of the warranty expiring it began to stutter at idle again. It helps to not fill the tank completely. However, it smells of fuel and continues to stutter at idle. We will not spend another $1500 to replace the tank as with the design flaw the issue will just reoccur. …
After fueling, as I pulled out onto the highway, the car stalled. I was able to coast to the side of the highway and restart the engine. It happened several times last year, always after fueling, and is becoming more frequent since December of 2014. Depending on where it occurs, it is extremely dangerous to stall when entering a steady flow of traffic. I've researched this problem, and it is a fact that it is common in Chrysler vehicles, particularly those with mileage over 100,000 thousand miles.......to my knowledge there has been no recall on this problem, and information that I've researched says that Chrysler doesn't consider it a problem. They suggest taking the vehicle to a dealership for analysis.
Tl* the contact owns a 2004 Chrysler Town and Country. While driving approximately 55 MPH after filling the tank with fuel, the vehicle stalled. The contact coasted to the side of the road and waited approximately three minutes. Afterwards, the vehicle restarted and operated normally. The failure recurred right after filling the vehicle with fuel approximately nine times. The vehicle was driven to the dealer, but was not diagnosed. The manufacturer was notified on the failure. The contact also received a recall notification for a fueling issue with the vehicle. The NHTSA campaign number was unknown. The approximate failure mileage was 93,000.
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.
After gas fill up van shuts off no warning steering locks, thank god I never had a accident this is a very serious problem. I noticed alot of other complaints Chrysler should recall this problem. I know they know about it so fix it . Would they want to drive this vehicle with a very serious problem who knows maybe there has been alot of accidents from this. How many claims have there been for accidents. We bought this used and it happens everytime you fill up. Maybe that's why they got rid of it.
After refueling the van the engine starts easily, I then pull out into traffic and then the engine stalls out in traffic. This only happens after filling the tank full. Usually will restart after the starter cranks a bit. Then the van runs fine until I refill the gas tank again. This has happened on numerous occasions since I purchased the vehicle used three years ago. Your form only has room for one occasion to report.
Car stalls when full gas tank. Doesn't happen every time, but it's always when full. Makes very unsafe condition. I've learned not to make left turns in first 5 minutes after filling, or best not to fill. It's a common problem when looking online, Chrysler replaces tank for valve on tank for some people. They refuse to do anything for me, but offer a $1500 fix. It truly is a widespread safety hazzard.
The car will sometimes cut off after fueling and snells if gas fumes. The service engine light came on and tge car would not pull in drive later car will not engage in the reverse gear. Car has been sitting for almost 2 months since thus happened. The car not pulling was while driving had to be towed home.
After filling fuel tank up, I drove out of station and van stalled and quit running. I started it up again, drove about 100 feet and it stalled again. This has happened 4 times after filling up with gas.very dangerous pulling into traffic out of gas station!
NHTSA investigations
Engine Stall After Refueling
This defect petition evaluates July 7, 2014 allegations from an owner of a model year (MY) 2007 Dodge Grand Caravan minivan that engine stall occurs in these vehicles without warning after refueling.The petitioner's vehicle is a Chrysler RS platform minivan.The RS platform includes MY 2003 through 2007 Dodge Grand Caravan, Dodge Caravan, Chrysler Town and Country and Chrysler Voyager minivans.NHTSA evaluated the…
Fuel System complaints in other Town and Country years
Frequently asked questions
How common are fuel system problems on the 2004 Chrysler Town and Country?
NHTSA has 58 complaints about the fuel & propulsion system of the 2004 Chrysler Town and Country, 35% of the model year's 167 complaints. The component named most often is storage › tank assembly (1 mentions).
Is there a recall for 2004 Chrysler Town and Country fuel system problems?
No. NHTSA lists no fuel & propulsion system 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 fuel system problems start?
Half of the complaints with a recorded mileage happened before about 84,000 miles, and 11% 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.