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 Grand Caravan owners, lightly cleaned up (personal details are redacted by NHTSA).
Several times in past year after filling the gas tank, shortly after driving away from gas station the engine misfires and stalls. This has been a safety hazard when merging into traffic. This problem is widely noted in forums on the internet for Chrysler minivans, for many other model years including the 2005. The best explanation being given (link follows) is that the vapor/liquid separator valve on top of the fuel tank has failed, a part that is not replaceable--the entire fuel tank must be replaced. Some report it happened when their minivan was brand new. https://ricksfreeautorepairadvice.com/engine-stalls-after-filling-tank-chrysler-minivan/
For some reason my caravan has started leaking gas from on top of the gas tank. not sure why, but I heard the was a recall but it was over 15 years ago so you people don't list anything older. i've only had the car a couple months, and also having a catalytic converter problem as well..
Last night - for the 4th time now - after filling the tank at the gas station, my car just died. The first 3 times it was when I stopped at the stop sign leaving the gas station parking lot. Last night, it was after I was out on the main road and in heavy traffic. It was stop and go rush hour traffic, so I was thankfully only going approx 15-20 miles an hour. Power steering was lost, brakes were practically non existent. Barely managed to pull off into a parking lot and was able to set the parking brake to finish stopping. Once stopped and in park, was able to start it right back up. Every time this has happened it has been right after fueling up. I never thought much about it the other 3 times, but this time was different, and very dangerous. …
Turned vehicle on, vehicle would not turn over at first, like it wasn't catching. Upon second try to turn over engine it did finally turned over and vehicle was running. That's when I noticed a strong smell of gas on the driver's back passenger side. Inspected undercarriage and noticed what appeared to be fuel had run down tank and was slowly dribbling. There was a small puddle of fuel on ground directly where dribble was. The family was on the way home from being out of town and we decided that we would drive it home before dealing with issue. Once vehicle was brought home I pulled fuel pump out of gas tank and noticed small hair line cracks. They appeared to look like dirt or dust had just settled into a "seam" of where the two parts of the plastic/material met, but was in fact a hair line crack. The fuel pump was leaking. …
On two separate occasions within the past month, the engine on my 2005 Dodge Grand Caravan stopped running while I was driving. On both occasions, it was within a mile after filling the gas tank. On one occasion, it occurred while I was making a left turn across oncoming traffic; I was lucky to be able to coast out of the intersection without being broad-sided. Since the engine stopped running, all power assist also stopped, so the car was very difficult to control. I have since read online that this is a relatively common occurrence with Dodge caravans, particularly with older cars. After filling up the gas tank, the engine May suddenly stop running within a short distance of the gas station. Apparently it has something to do with the gas tank venting, and the only remedy is to replace the gas tank. …
After filling the fuel tank up, the vehicle stalls, stutters, or shuts down after entering into traffic. After it does shut down, it is typically difficult to restart. The type of driving environment does not matter - city/community stop and go traffic or highway speeds for extended periods of time. After the vehicle is restarted, we do not have a problem again until the next time the vehicle needs to be refueled. The gas tank, fuel filter, and fuel pump were all replaced by the dealer prior to 100,000 miles to eliminated a high pitched whine coming from the fuel tank area every time the fuel level dipped below half a tank. Most of the time, the vehicle decides to stall or shut off as we are accelerating to join traffic - leaving from the gas station. On multiple occasions we have almost been hit from behind because the vehicle just stops. …
Smelled raw gasoline smell outside of vehicle after running vehicle. Occurred on two occasions on aug 23, 2016. Looked under vehicle on 8/30/16 and saw and felt liquid fuel on fuel tank in vicinity where fuel pump goes into gas tank. Leak occurs when ignition is in the on (running) position. Did online research and found that others have had same problem with fatigue cracks in plastic top of fuel pump, where fuel hose attaches. When key turned on and fuel pump is pressurized, fuel begins to leak through the hairline crack. Dangerous, as muffler and exhaust pipe are located less than one foot from the source of the leak!! Took vehicle to repair facility, who determined fuel pump module was leaking as described above. Cost over $500 to have new pump installed, even though the old fuel pump was still working, though leaking.
After refueling van, started vehicle and pulled away from pump driving onto the road applied throttle and engine died without notice just shut off. I am a technician have been for a long time and have seen this problem on many different makes and models the issue is the vent valve on my Dodge Grand Caravan its built into the fuel tank. Unlike my Dodge other brands like Nissan Honda etc.. Actually take care of their customer. Had traffic been busy we could have been seriously injured if not killed.I've read so many complaints for this issue all blaming vent valve and I agree. Something needs to be done and the manufacturer held liable. Dodge already had this same issue on Chrysler 300 and a few other cars and they made a lifetime warranty for those fuel tanks its time they do the same for the vans.
Filled up with gas, drove about 2 mins, slowed to turn left at intersection with stop light. My minivan then stalled while in the middle of the intersection. This is the third time the car has died after fueling. I replaced my battery and alternator upon recommendation by local auto parts store, but the problem persists. Dodge dealer service technician says "it's a common problem and being investigated" and said I need a new gas tank due to a bad valve and recommended replacing the fuel pump and filter while doing the maintenance, over $1000. I dread getting gas and won't let my wife drive the kids in the van anymore. It's a death trap waiting to happen.
2005 Dodge Grand Caravan stalls after refueling. This issue has been happening for about 3 years when the fuel tank gets low and then refilled. Most of the time the stall happens shortly after refilling and I come to a stop light or stop sign. There have been few occasions where the Caravan has stalled while in motion while travel under 20 MPH. I can usually restart the Caravan immediately after the stall. The only solution from online forums seems to be to replace the fuel tank and purge the valve and charcoal canister of any raw fuel. Seems like a common problem within similar models.
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 2005 Dodge Grand Caravan?
NHTSA has 64 complaints about the fuel & propulsion system of the 2005 Dodge Grand Caravan, 6% of the model year's 996 complaints. The component named most often is delivery › fuel pump (2 mentions).
Is there a recall for 2005 Dodge Grand Caravan fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for the 2005 Dodge Grand Caravan, though it has 5 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 Grand Caravan fuel system problems start?
Half of the complaints with a recorded mileage happened before about 105,000 miles, and 9% 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.