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 Ram 1500 owners, lightly cleaned up (personal details are redacted by NHTSA).
I recently figured out a problem with my truck that is an extreme danger. When you fill up the fuel tank at any gas station, it seems that the fuel enters the vapor canister and makes the engine stall for about a mile before it starts running properly. After several close encounters after filling the tank, I looked upon other threads of Dodge Ram owners and found this to be a common problem that was never addressed by Chrysler and never acted upon by NHTSA. Please look into this and advise a course of action to have Chrysler repair this problem.. It is a matter of time before either I or another with the same problem are seriously injured or killed due to this defect. Many Thanks In Advance!!
I tried to get the service done Iam a one vehicle owner the dealership told me I had to pay out of pocket for the rental car with no set day of service The dealership didn't care whether I got the recall done cause of the year of the vehicle they provided no transportation solution
I have a 2004 Dodge Ram 1500 when I get gas and fill up until the pump clicks (I do not top off tank) then upon pulling out of the gas station my truck stalls. If I stop for a red light truck stalls again and it continues to stall every now and then at low speeds, at a complete stop, when braking, slowing down, or at idle and last until I run some gas out of it (about 10 miles or so). Vehicle will start right up with no problem but battery gauge takes a few seconds to rise to operating levels. Transmission also feels like it wants to slip at time of stall. I took it to the dealership but because a code was not thrown it is my issue to deal with (have to drop the gas tank and replace a sensor in the overflow tube $500 plus dollars- which I do not just have lying around). …
I was driving my 2004 Dodge Ram 1500 on the highway when my truck stopped running. Found the fuel pump was no good. I have been an auto mechanic for years and this is very dangerious! I had it towed to the garage daves auto on madison ave told me the fuel pump was no good also the fuel tank is no good the ring on top of the fuel tank is rotten the "tabs that hold the fuel pump in is rotten" and where the fuel pump sits on the fuel tank is like in a well so when it rains the water on top of the gas tank sits in the fuel pump location has no where to drain and my thery is that is what rotts the fuel pump bracket on the fuel tank! And they said it is not safe I had to get a new fuel tank. I called multipul used auto parts supply companys and every single one who had a gas tank had the same problem was rotten. …
For a few weeks I would occasionally smell gas fumes. I had the truck visually inspected and the mechanic could find nothing wrong. Then one day I filled the tank. When the tank was full, instead of the pump shutting off the pump began pouring gas onto the ground. This time they dropped the tank to find that the metal collar on top of the tank had rusted away causing the fuel pump to pop up half out of the tank. That was the reason the pump had not shut off . Gas was flowing out of the top of the tank!!. The mechanic told me that if the fuel pump connection had shorted out with the top of the tank open the way it was ,me and anyone in the truck would have been blown up!!!. This was a very poor design on Chrysler's part that has the potential to kill people.
As stated in other complaints, the vehicle will stall after slowing down at intersection of driving in heavy traffic. If you ride the brake and gas, you can keep from stalling. This incident started to happen after a smell of gas vapor smell after filling tank. Researched stalling and gas smell, was LED to other scalp notice for Hemi gas tank due to ethanol gas causing the rollover valve in the gas tank to expand and not close. When you fill the tank you get liquid gas in the purge vapor canister and line. This giving you the gas smell upon filling. I have stopped filling the tank past 3/4 and have not had the issue since. Kind of disappointed that other Hemi models gas tanks were recalled, but not the truck even though it has the same issue.
Vehicle stalls after a gas fill-up. Dealer had filled the vehicle up and it stalled repeatedly for about 10 miles and then was fine. The next time I filled it up it stalled repeatedly again. I returned it to dealer for repair. They replaced the charcoal canisters and purge valve solenoid. After the next fill up it did not stall. However, after the second fill-up it started missing at highway speeds and then stalled on an exit/entry ramp of short curvature and had to be hurriedly restarted while turning at high speed. This is a definite safety issue and should be a recall. Social media is rampant with this issue with dodges. Not filling the tank with gas is not a solution to this problem as some would suggest. This needs to be rectified!!!
I purchased this 2004 Dodge on January 5th 2015. I was to return on January 7th to have different tires & rims installed. On the way I stopped and filled the gas tank. Afterwards every stop sign I came to the vehicle stalled out. It started right back up but continued to stall at every stop sign. The mechanic at redding truck & auto diagnosed that the crank sensor was bad and replaced it at no charge. It ran fine until I filled the gas tank again and started having the same problems with it stalling out. So now if I fill the tank it will stall out until I drive it for several miles or until I run some of the gas out of the tank. I was told not to fill the tank which is not a fix for this problem.
A whining sound started coming from somewhere on the vehicle approx 30 min before the rear end exploded locking the vehicle up and causing the drive shaft to fly across two lanes of heavy holiday traffic. Thank the lord no one was injured or accident was caused due to this failure of a loose pinion nut on the drive shaft. I had it towed to the closest dealership who said it will cost over 4500 dollars not including car rental to get it repaired, the dealer said they contacted the mfg. And they said it was not under the recall. This is a serious and dangerous problem. This vehicle has been dealer maintained since new and should not have experienced this issue without a recall or warning.
We were driving on the highway 55 MPH and heard a noise while exiting and we thought we hit a large hole. Before we reached the end of the off ramp traveling at approximately 50 MPH but giving the truck some gas to accelerate we heard a very loud pop and it felt like something hit the bottom of the truck.we pulled off to side and checked under the truck to see the slip yolk and u joint of the driveline were broken and the flange nut on rear end was backed off and the rear end was shattered. Also the fuel vapor recovery lines were broke from the slip yolk and u joint breaking. Is this issue related to recall number 14v79600
Fuel System complaints in other Ram 1500 years
Frequently asked questions
How common are fuel system problems on the 2004 Dodge Ram 1500?
NHTSA has 62 complaints about the fuel & propulsion system of the 2004 Dodge Ram 1500, 6% of the model year's 1,099 complaints. The component named most often is fuel injection system (2 mentions).
Is there a recall for 2004 Dodge Ram 1500 fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for the 2004 Dodge Ram 1500, 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 2004 Dodge Ram 1500 fuel system problems start?
Half of the complaints with a recorded mileage happened before about 84,000 miles, and 9% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 1 fire and 0 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.