2005 Chrysler Town and Country Fuel System Problems

Which parts fail

• Delivery › Fuel pump
  5
• Storage › Tank assembly
  3
• Fuel injection system
  1
• Storage
  1
• Storage › Fuel gauge system
  1
• Storage › Auxillary tank
  1

Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).

Mileage when the problem started

• Under 25k
  910%
• 25k–50k
  89%
• 50k–75k
  2629%
• 75k–100k
  1921%
• 100k–150k
  2427%
• 150k+
  44%

Owner reports

Selected complaints filed with NHTSA by 2005 Chrysler Town and Country owners, lightly cleaned up (personal details are redacted by NHTSA).

Problem started 01/2011 at approximately 100,000 miles.vehicle stalls after filling gas tank. If you fill tank and pump shuts off the vehicle will stall after a couple minutes. Doesn't happen all the time but, about 85% of the time. It stalls anywhere from 1-3 times. It has stalled when I was in traffic driving and when I sit stationary and wait for it to happen before driving. Almost got rear ended on a couple of occasions. Had a repair on it at the dealer on 03/17/2011. They replaced the EVAP canister. Copy attached. It fixed the problem for about a year and a half and then it came back. I've seen lots of complaints on the internet for the same issue. I've read that the only fix is to replace the entire fuel tank. I can't afford that. For years now I've been sitting at the pump for 5 minutes after fueling or I don't fill the tank all the way up. …

After filling up gas tank and re-starting the engine, the engine either stumbles or stalls 1-5 times beginning within about 60 seconds of starting engine and driving away from gas station. This has been happening repeatedly over the last year and has become more frequent in the past 6 months. At least twice, it has stalled while pulling into an intersection right after fill up. After about 5 minutes, the stumbling/stalling stops and doesn't recur until after the next fill up. It occurs during both low-speed driving (e.g. Waiting at a light) and at high-speed driving (e.g. Merging onto interstate highway immediately after filling up) online forums indicate this is a common problem with this make vehicle and say the only fix is replacement of the entire gas tank. …

Fill up with fuel (not topped off, just until the pump clicks off) and the car starts, but after going several hundred feet, the engine starts to sputter and choke, then the car dies. Must restart and usually it still chokes and sputters, but then will seem to resolve once you step on the gas and will not typically stall out until the next fuel up when we rinse and repeat the same experience. This happens every time I fuel up and has for over three and a half years. I finally decided to do some research on it because it's very nerve wracking as it happens once you leave the service station and are out in traffic. This is extremely dangerous and needs to be addressed before someone is killed because of a faulty gas tank! I found that Chrysler has addressed this problem with some of their vehicles this is occurring to, but not the minivans. …

This is dangerous - car stalled while on highway and during a turn, locking out the steering system and putting my car into oncoming traffic. This happened after filling the car up with gas - as with other Chrysler models of this year, it looks like there is a problem with the valve in the gas tank. I experienced sputtering after gas fill ups two days prior, and this final fill up the engine completely died. I had my whole family in the car. Fortunately we avoided an accident, but if we had been in one and survived I would have sued. There is a whole forum online at this address of people who have experienced the same issue and have been put in dangerous situations. Http://en.allexperts.com/q/Chrysler-repair-807/f/stalling-refueling.htm.

I began having the exact same complaint as the 2004-5 Dodge vans have with regard to stalling about 1 minute after a fill up. It has happened at every fill up since December 2015, and sporadically before, but I did not recognize the source of the stalling. I called Chrysler and they told me my van was made in the windsor (affected plant) on 6-10-2005 but that the recall/repair shut off in April, I believe. It seems too big a coincidence to me. This has been dangerous since on some trips, I am on the interstate getting gas and get back on when the stall occurs. Is there any recourse for me? It has been occuring ever since December, that is when it started, at least that is when it has been happening without letup.

At approximately 105,000 miles I began noticing a strong smell of gasoline both inside & outside the vehicle- running or not. At about the same time I noticed a big drop in fuel efficiency. We are now getting an average of 10 mpg. The norm is an average of 19 mpg. The vehicle starts fine & there are no check lights on. I believe the acceleration is also slower now. Our family is the original owner & the vehicle has never been in an accident. Common sense tells us this is a very serious safety issue. There seem to be many others with this same issue & it's disappointing to find nothing is being done about it. We are a one car family & we have no choice but to drive this vehicle.

Tl* the contact owns a 2005 Chrysler Town and Country. The contact stated that the vehicle failed to start and several attempts had to be made before the vehicle could restart. In addition, the contact mentioned that an odor of fuel emitted inside the vehicle. The vehicle was taken to an independent mechanic for diagnosis, who noticed that an excessive amount of fuel was leaking onto the ground, as a result of a ruptured fuel line. The vehicle was not serviced because the dealer informed that the part needed had not been available for over a year. The manufacturer was not notified of the failure. The approximate failure mileage was 82,000. Ma 10/15/2015 updated 12/12/16

After refueling the van stalls at least once but May stall up to three times. The engine surges in RPM before stalling. Restart after a stall can sometimes be difficult. I have let the van idle for several minutes after refueling but it does not stall while stationary. It usually occurs within a minute of operation on the street and generally while pulling out of the gas station lot onto the roadway. Once the car has been driven for a few miles there are no other occurrences of stalling until it is refueled again. The issue used to be infrequent a few years ago but is no occurring after every refueling.

Vehicle starts up and as you accelerate into an intersection the van dies. Mechanic replaced intake manifold and related sensors and check the computer but believes the problem is the wiring harness. Diagnostic was run on the computer and that is not the problem. Mechanic thought he had fixed it but 2 minutes out from the mechanics shop the vehicle died and kept dying as I pressed on the accelerator. I had to make it back to the shop going about 5 miles per hour. After a $843 repair bill the van still won't run without dying and is dangerous to drive.

Stalling after refueling began on our vehicle about a month ago. Today, with my son in the van, it stalled on the highway 610 garrisionville, stafford va.. The danger was that I was on a turn and the steering wheel became impossible for me 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) it seems to stall after filling and have not yet had it happen again till I refuel the tank..

NHTSA investigations

Fuel System complaints in other Town and Country years