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 Dodge Caravan owners, lightly cleaned up (personal details are redacted by NHTSA).
I had this van 2005 Caravan for about 5 years and past year I had 3 issues, one of them is that my lights turned off right in the middle of highway and it was very scary , I fixed it by replacing the light switch and now is OK but it should be looked into because there is more incidents of that type on other caravans as I can see,second is my airbag sensor light comes ,stays ,goes away and then comes back up as it wills ,I did not fix it since I don't know how to but will try to get it done as a recall, third one is my fuel pump is leaking at a same point where I saw pictures and complaints by other owners so I would like just to add my own complaint,I will replace my fuel pump since I doubt I can get recall in near future but hopefully keep the receipt if it gets approved so I can try to get my money back,thank you for your consideration.
My van when I fill it up would runn so ruff and then would die trying to cross the street. Then it started smelling like gas when I filled it up.. Then it started smelling like gas and trying to die when I filled it up. So as long as I dont fill it more than half way I was OK. My son finds out about this and makes me take the car in. They tell me it is the fuel pump, fuel tank and cannister. I ask how can it be all 3 ? Go head and take it apart and make sure whats proken and fix it. They say its under recall and needs a new tank and cannister but pump is not included. Well if it pumps fine under half a tank and runs fine under half a tank then what going on. They replace everything cnly charge me 7.00 for labor but 397.00 for parts. A month later call me back to replace it all again. They never shower me the bad parts as requested.
When filling with gas the engine turns off while driving, this happened on a left turn with vehicles approaching, cars had to stop and help push van out of street. Luckily it did not cause an accident, had two young children in vehicle , very fortunate for the quick response of other drivers. Fuel reading wrong first time car shut off while driving showing 1/ 4 tank of gas. Now shuts off showing more than 3/4 tank of gas this happen on the highway, lost all power steering as well. Again I had two young children in car. Seat belt not working properly. Headlight very dim at night not good few for night time driving. This vehicle is becoming more unsafe to drive.
The vehicle has the strong smell of gasoline. When parked and being driven the gas fumes are strong. I changed the fuel tank, that did not fix the problem. If the windows are opened the fumes enter the cab. When open the door, I have to stand back and let the fumes dissipate before getting in. I cringe when a lit cigarette is thrown out ahead of me. Is this the time that I will go up in a blaze of glory? What has to happen to get this problem fixed?
Just filled up with fuel, started to pull in to traffic, engine stalled. Almost broadsided by a semi. Now every time I fill up, the engine stalls upon acceleration. Upon doing some checking I have found that I am not the only one with this problem, and that the problem is a faulty valve in the fuel tank. Somebody is going to die because of this all of a sudden hesitation. There are hundreds of these people having this same problem. How come no recall?
Tl* the contact owns a 2005 Dodge Caravan. The contact stated that a smog test detected a fuel leak from the fuel tank. There were no warning lights illuminated. The contact stated that there was a strong fuel odor outside of the vehicle prior to the smog test being performed. The vehicle was not taken to be diagnosed nor repaired. Neither the dealer nor the manufacturer was contacted or informed of the failure. The failure mileage was 148,936.
When pumping gasoline into the tank, within a few seconds the gasoline backlows and turns off the pump. In order to get 5 gallons into the tank it May take 20 stops, wait & starts which May take 5 minutes. The charcoal vapor trap is working fine since the hose to it from the gasoline tank was disconnected to test the vapor canister. Mechanic does not have a clue how to resolve this problem. This is an ongoing problem for over a month and a half.
Top of the fuel pump is made of plastic and was found cracked in two places. Internet search yielded many other examples with photos showing cracks in exactly the same place. Result of these cracks is a fuel leak as well as strong gas fumes in and around the vehicle resulting in an obvious fire hazard. Leaks at all time that the vehicle is running as well as for some time after the vehicle is stopped and parked.
My van stalls everytime I fill up the tank. I do not tap off the tank I fill it till the handle clicks once and thats it. I have done a ton of research and found that its the fuel vapor separator. Then only way to fix said problem which is totally common on all chysler vans the way I am reading it is that I have to replace the entire fuel tank. It stalls after filling up and when I start to drive.
Purchased used 2005 Dodge Caravan with 100000 miles and it was leaking fuel around the fuel pump, took it to merlins to have it checked out resulting in replacement of fuel pump modeule due to the fact it was cracked and had to be replaced.
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 Caravan years
Frequently asked questions
How common are fuel system problems on the 2005 Dodge Caravan?
NHTSA has 37 complaints about the fuel & propulsion system of the 2005 Dodge Caravan, 7% of the model year's 537 complaints. The component named most often is delivery › fuel pump (2 mentions).
Is there a recall for 2005 Dodge Caravan fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for the 2005 Dodge Caravan, though it has 4 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 Dodge Caravan fuel system problems start?
Half of the complaints with a recorded mileage happened before about 100,000 miles, and 10% 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.