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 1996 Dodge Caravan owners, lightly cleaned up (personal details are redacted by NHTSA).
The contact owns a 1996 Dodge Caravan. The contact stated while driving at an undisclosed speed, there was a strong gasoline odor inside the vehicle. The contact stated that after parking the vehicle, he opened the hood and noticed a fuel leak on top of the engine. No warning lights were illuminated. The contact made a local dealer aware of the failure; however, the vehicle was not yet diagnosed or repaired. The manufacturer was not made aware of the failure. The approximate failure mileage was 130,000.
Tl* the contact owns a 1996 Dodge Caravan. The contact was driving 30 MPH when he was advised by another motorist that fuel was leaking from the top of the fuel tank. The contact had just refueled the vehicle. The vehicle was taken to a local mechanic and the contact was advised to replace the catalytic converter. The mechanic also stated that there was evidence of a small fire from the fuel tank. The mechanic referred the contact to the dealer to inquire about a potential recall on the vehicle (NHTSA campaign id number: 99V216000, fuel system, gasoline: delivery fuel pump). The dealer advised that the vehicle was included in the recall but the dealer refused repairs because of the damages from the small fire. The vehicle was not repaired. The failure mileage was 156,398 and the current mileage was 156,432.
In fueling our van, on two different occasions, we have had a fire. The fire comes from the filler pipe on the van! The van was totally turned off. It does extinguish itself after awhile. We are experiencing shock constantly when we touch the van. We have had it to the dealer about the shocking problem, but not the fire. We assumed it was with our personal gas tank. Contacted the gas co. And they investigated and corrected what could have been a problem. No other vehicals that are filled at this tank have experienced this difficulty. My son and I were involved the first time there was a fire. He was burnt slightly. The second time, only myself. We are concluding now, that the difficulty is within the van. We are contacting a dealer in the am but would you please assist. Not only was the filler pipe on the van on fire, the hose from the stationary tank and the ground was on fire. …
Consumer was driving at 25mph on the highway. He was looking in his rear mirror and he noticed smoke trail. Gasoline was dripping from underneath the pipe, and the car was on fire. When he applied brakes,the car kept moving. The vehicle cut off in the middle of highway traffic going 55 MPH due to a faulty fuel pump which the manufacturer replaced. 15 months later fuel began to leak from underneath the vehicle causing fire while the customer was driving.
Tl contact owns a 1996 Dodge grand Caravan. The contact stated that fuel was leaking from his tank in large amounts. The vehicle was inspected by a independent mechanic and they advised him that he needed to replace the tank and the fuel pump. The vehicle has not been repaired. The manufacturer was contacted and advised him that the recall was expired and could not assist him. The failure mileage was approximately 151,000. Updated 03/24/11 updated 05/02/11
Tl contact owns a 1996 Dodge Caravan. The contact stated that the fuel tank causes fumes to enter the passenger compartment of the vehicle, as well as fuel leakage. He stated that the fuel tank was replaced a year ago, but still emits fumes. The vehicle was previously repaired under recall # 99V216000 (fuel system, gasoline:delivery:fuel pump). The incident and purchase dates were unknown. The current mileage is 165,000 and failure mileage was 100,000.
Tl contact owns a 1996 Dodge Caravan. The vehicle was repaired according to a recall, but the failure has resurfaced. Fuel is leaking from the fuel rail into the engine compartment, which is a fire hazard. The dealer stated that the contact would be responsible for the repair cost. NHTSA campaign id number 00V268000 the failure mileage was 150,000. Updated 03/23/09. The consumer stated the dealer fixed the recall for recall. Updated 03/23/09.
Vehicle suffered three fuel tank failures. In between the three failures the consumer had the vehicle in the repair shop on multiple occasions to have the fuel system inspected. Because the smell of fuel was so powerful windows had to be closed while operating the vehicle. The dealer was notified about the defective fuel pump assembly and refused to reimburse the consumers for repairs made. Please respond promptly in resolving matters.
Driving vehicle when other drivers noticed flames coming from fuel tank. Barely out of vehicle when it was engulfed by flames. Had no warning & smelled no smoke. Insurance adjuster & mechanic said fire was caused by hole in fuel tank, causing it to leak & ignite. There's recall #96V002000. After the recall item was repaired, owner experienced battery and computer related failures.
Consumer was traveling about 55mph on highway and vehicle started losing power, also there was gray smoke coming from underneath of vehicle. Dealership was aware of problem. Consumer states the manufacturer issued a recall #895 for fuel rail o-ring leak, but was not implemented. This causes the engine compartment to cathch on fire.
Related recalls
Fuel system, gasoline › Fuel injection system
Vehicle description: Mini vans built with 3.3l and 3.8l engines have fuel rails with nitrole rubber o-ring seals that can degrade over time. Fuel leakage from the underhood fuel injection fuel rail could result, increasing the likelihood of a vehicle fire.
Remedy: Dealers will install a seal on the vehicle fuel rails to prevent external leakage of fuel from the fuel rail crossover tube, should the existing o-rings continue to degrade. Owner notification began on January 25, 2002.
Fuel system, gasoline › Delivery › Fuel pump
Vehicle description: minivans. Fuel can leak from the fuel tank at the interface of the fuel pump module attachment.
Remedy: Dealers will replace the fuel pump module attaching nut with a nut that includes tighter design tolerances. The sealing o-ring will also be replaced.
Fuel system, gasoline › Storage › Tank assembly › Filler pipe and cap
A static electric charge can build up on the ungrounded metal section of the fuel filler tube.
Remedy: Dealers will install a ground strap for the fuel filler tube.
Fuel system, gasoline › Delivery › Hoses, lines/piping, and fittings
The fuel tank rollover valve can allow fuel to pass into the vapor canister resulting in the potential for fuel leakage.
Remedy: Dealers will replace the fuel tank filler tube with a filler tube that has an additional rollover valve. The associated rollover valve vapor hoses will be rerouted.
NHTSA investigations
Post-collision fuel system integrity
There is no summary currently available
Post collision fuel system
Fuel System complaints in other Caravan years
Frequently asked questions
How common are fuel system problems on the 1996 Dodge Caravan?
NHTSA has 222 complaints about the fuel & propulsion system of the 1996 Dodge Caravan, 16% of the model year's 1,403 complaints. The component named most often is storage › tank assembly (99 mentions).
Is there a recall for 1996 Dodge Caravan fuel system problems?
Yes — NHTSA recall 00V-268 (fuel injection system, Sep 13, 2000); NHTSA recall 99V-216 (fuel pump, Aug 9, 1999); NHTSA recall 96V-002 (filler pipe and cap, Jan 16, 1996). Recall repairs are free at authorized dealers.
At what mileage do 1996 Dodge Caravan fuel system problems start?
Half of the complaints with a recorded mileage happened before about 124,000 miles.
Is it dangerous?
Owners linked 0 crashes, 16 fires and 3 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.