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 2006 Dodge Grand Caravan owners, lightly cleaned up (personal details are redacted by NHTSA).
Upon refueling, the vehicle experiences a delayed stall, meaning that the vehicle does start without hesitation; however, within a few yards of driving, the vehicle stalls. More specifically, it stalls upon braking to yield or turn just after fueling. Once the vehicle stalls, it can be restarted and the problem does not present itself again until the next fill up. This is a safety issue as the vehicle May stall in the middle of entering a busy street potentially causing an accident. This gets progressively worse with each fill up because although the engine does turn over, it takes longer to do so each time and May eventually not turn over at all. Internet research and diagnostic from a certified mechanic indicate that it is the liquid separator valve. Further research shows that this is a common problem with Chrysler minivans. …
Investigation: dp 14-002; prompted by: defect petition; date opened: 09/05/2014; investigator: [redacted]; reviewer: [redacted]; approver: [redacted]; subject: engine stall after refueling. Please include me in the above mentioned complaint/investigation # dp 14-002. After refueling, my engine stalls about 1 to 2 minutes after starting almost every time I fill-up with fuel. When the fueling nozzle trips for the first time, I do not attempt to continue adding more fuel and possibly overfilling the fuel tank. I have been caught in heavy traffic at times with the engine stalling and it takes 2 to 3 attempts to restart the vehicle. This is very dangerous! Now after refueling, I pull away from the pumps and park out of the way and allow the engine to stall. …
I have a 2006 Grand Caravan and lately, everytime I fill it up, it stalls out on me a few times. I almost got hit pulling out onto a highway last week.I called the dealership and he was aware of the problem. Said I should not fill the tank because it would overflow on some valve causing the stalling. He had other customers complain. My question is, why is this not fixed?. I need to fill my tank as I travel a lot. I don't want to stop and get gas often. And I sure don't want to get hit trying to leave the gas station. I got online and looked up complaints. Here is just one list I found. Http://en.allexperts.com/q/Chrysler-repair-807/f/stalling-refueling.htm with this being a major problem with so many, I think Chrysler should have a recall for the safety of so many people. I never had a problem until recently so this tells me, something is faulty in the gas tank. …
After fueling my 2006 Dodge Caravan it will stall, or sputter to almost stalling then rev up and almost stall again several times. After a few times of stalling and sputtering it then runs fine. The problem is that this happens usually right after pulling out of the gas station, which usually involves pulling out into traffic. Two times this happened, before I know better now, it happened after pulling out onto the road and stalling in the middle of 4 lane roads. Luckily the first time there was no traffic and the second time I was going downhill on a straight road and was able to coast until I got the van started. Although I am aware of the problem now, this could be dangerous. Also this is a business vehicle and people other than myself drive the vehicle. My employees May not be able to react to a stall in the middle of a road as I am.
This problem started in August of 2014 but it is ongoing and happened as recently as March 27, 2015. Every time I fill up the gas tank on my 2006 Dodge Grand Caravan, the car stalls out while we are driving. Eventually, we are able to start the van back up and keep driving. After that, it drives fine until we fill up the tank again. One time we stalled out and the van did not start back up so we replaced the fuel pump. The van started back up but the issue returned again. It happens every time we fill up. This seems to be an ongoing issue that many people have. I believe it is related to defect petition dp 14-002. Http://www-odi.NHTSA.dot.gov/acms/cs/jaxrs/download/doc/ucm461759/inoa-dp14002-5470.pdf. I believe that Dodge needs to issue a recall and fix the fuel tanks which contain the faulty fuel valves causing this problem.
Starting about a year ago, my 2006 Dodge Grand Caravan engine stalls after refueling, usually when making a turn, but sometimes when just driving straight. A few times I have almost been in serious accidents because of it, the most serious stall occurred in a busy intersection. The stalling occurs after about 90% of my fill-up times. It occurs on the first drive after refueling but I don't know when it will happen. I called Dodge and spoke to jarred on 3/2/2015 at 1:00 pm but he would not say if Dodge/Chrysler has any knowledge of the problem. He just said that it is not on their recall list. I hope that the NHTSA can push Dodge to create a recall for this problem, which I believe is a defective gas tank or part of the gas tank.
Tl* the contact owns a 2006 Dodge Grand Caravan. The contact stated that the vehicle stalled without warning. The contact mentioned that the failure recurred after the vehicle was refueled. The vehicle was restarted. The failure recurred numerous times. An independent mechanic diagnosed the vehicle and stated that the fuel tank needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was 121,000. ......updated 04/01/16
After filling up with gas engine stalled approximately 1/2 mile from the gas station. Had to coast to side of the road without power steering. Placed engine in park, turned of key and restarted. Engine ran rough had to depress accelerator for additional gas. Once restarted engine ran fine for the rest of the trip. This same problem also occurred in early January 1/03/2015 after filling up with gas. Not only is this an inconvenience, but very dangerous in heavy traffic scenarios.
I came across the NHTSA action number dp14002 when looking for internet info about other problems with the 2006 Grand Caravan. The NHTSA summary describes an ongoing problem that we have with this Mini-van: if you completely fill the fuel tank you are quite likely to have the vehicle stall within the first quarter-mile of driving. I am sorry see that this action has been closed!
Tl* the contact owns a 2006 Dodge Grand Caravan. While driving at 30 MPH, the vehicle stalled. The contact stated that the failure occurred immediately after the fuel tank was filled. The vehicle was not diagnosed nor repaired. The manufacturer was notified of the failure. The approximate failure mileage was 150,000.
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 2006 Dodge Grand Caravan?
NHTSA has 31 complaints about the fuel & propulsion system of the 2006 Dodge Grand Caravan, 11% of the model year's 286 complaints. The component named most often is storage › tank assembly › filler pipe and cap (1 mentions).
Is there a recall for 2006 Dodge Grand Caravan fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for the 2006 Dodge Grand 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 2006 Dodge Grand Caravan fuel system problems start?
Half of the complaints with a recorded mileage happened before about 96,000 miles, and 7% 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.