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 Dodge Grand Caravan owners, lightly cleaned up (personal details are redacted by NHTSA).
I went to the gas station and filled my gas tank, not topping it off, and as soon as I turned out of the station on a major road the vehicle stalled and almost resulting in an accident. After a quick restart the van ran fine and I was able to drive from nashville, tn to atlanta, ga with no problems. But when I filled up again in atlanta, right after pulling out of the gas station the vehicle stalled again, in the middle of a busy intersection. This problem is widely reported across Dodge and Chrysler vans, with over 100 complaints on this website. I'm hoping this issue with the gas tank/sensors will be address. Thank you.
While making left the vehicle stalled while in motion in the middle of major intersection. After a 20 or so seconds, the vehicle engine turned on. Another incident, approximately a year ago, while traveling 60+ miles on major interstate, the vehicle again shut down while in motion. I had to coast the vehicle, with loss of power, to median on the interstate. After about a minute or so, the vehicle turned on. Always upon filling the gas tank, the vehicle stalls while exiting the gas station or shortly thereafter. After a minute, the vehicle is able to turn back on.
Tl* the contact owns a 2004 Dodge Grand Caravan. While driving 45 MPH, the temperature gauge on the instrument panel started going to the red side; indicating that the vehicle was having trouble regulating the engine cooling system. The contact also stated that there was a strong odor of fuel entering the vehicle. The vehicle was taken to an independent mechanic where it was diagnosed that the fuel pump and carbon filter needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure. The failure mileage was 100,000.
Every time I fill my tank (I do not top off), within a few minutes of leaving the station, the van dies. It normally re-starts, but it takes quite a lot of gas pedal pumping. This is dangerous when it happens in the middle of an intersection. I had the fuel pump and filter replaced and that did not solve the problem. Now I understand that the valve on top of the tank is at fault, but you have to replace the entire tank. This is a design flaw and needs to be corrected.
After filling my '04 Grand Caravan with fuel and attempting to leave the pump my Caravan shuts off. This has been on an ongoing issue for over 2 years. After several repair attempts I was told today that the vapor separator valve located on top of the gas tank is faulty. A valve that Dodge does not make available for repair. The only "fix" that is offered is to replace the entire tank of which I was told today would be $1600.
Hairline cracks in fuel pump outlet just before connecting to fuel line leads to strong fuel smell and fuel vapors all around vehicle. Fuel pump needs replacement to repair this dangerous condition. Highly suggest different fuel pump design that is not prone to hairline cracks and potential fire hazard as fuel leak is about one foot away from a hot muffler and a tossed cigarette or other spark could cause a fire or explosion.
After filling the gas tank, within a few miles the vehicle will stall. Dodge already has extended the warranty on the fuel tank of vehicle built after September 2003 but mine was built August 5 2003 so it is outside their window. This is a very dangerous issue because it has happened to me on the highway at 55 miles an hour and I then have no power and need to get out of the way of traffic that is going to run me over.
Tl* the contact owns a 2004 Dodge Grand Caravan. The contact stated that after refueling the vehicle, it stalled without warning. After several attempts the vehicle was able to restart but the failure recurred. The vehicle was not diagnosed or repaired. The manufacturer was notified of the failure. The approximate failure mileage was 70,000.
After fueling the check engine light is now on and indicates an emissions leak which causes vapors to now build up inside the van after every refueling. If filled to capacity the vehicle will also stutter and sometimes completely stall shortly after fueling.
2004 Dodge Grand Caravan fuel tank vapor float vent failure. Vehicle has 59,000 miles. After fueling vehicle it will stall intermittently at stop signs and on open highway without warning, because fuel is getting into the engine and flooding engine out via the tank venting vapor system. When fueling, a float in the orvr (onboard refueling vapor recovery) valve is designed to rises and seals the tank vent causing pressure build, backing fuel up into the fill neck and shutting it off. The orvr is apparently not sealing completely or at all, allowing liquid fuel to pass into the vent line to the vapor canister and then engine. The valve is plastic welded to the tank, which requires the tank to be replaced. Major safety issue because the power steering system stops when engine stops and vehicle is not able to be steered without the power steering aid. …
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 Grand Caravan years
Frequently asked questions
How common are fuel system problems on the 2004 Dodge Grand Caravan?
NHTSA has 36 complaints about the fuel & propulsion system of the 2004 Dodge Grand Caravan, 31% of the model year's 116 complaints. The component named most often is storage › tank assembly (2 mentions).
Is there a recall for 2004 Dodge Grand Caravan fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for the 2004 Dodge Grand Caravan, 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 Dodge Grand Caravan fuel system problems start?
Half of the complaints with a recorded mileage happened before about 100,000 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.