2005 Dodge Grand Caravan Fuel System Problems

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..

REPEATEDLY THE VEHICLE WILL LOOSE POWER AND STALLS OUT AFTER FILLING THE TANK WITH FUEL. IT WILL OCCUR WITHIN LESS AND 1/8TH OF MILE AFTER PULLING OUT OF THE GAS STATION. THE VEHICLE HAS DONE THIS REPEATEDLY IN INOPPORTUNE SITUATIONS, LIKE TRAVELING UP A STEEP HILL AND AT A BUSY INTERSECTION. WE ARE ORIGINAL OWNERS AND HAD NEVER HAD AN ACCIDENT WITH IT . IT HAS JUST UNDER 120K MILES ON IT.

I HAVE A FUEL LEAK UNDERNEATH FROM THE TOP OF FUEL TANK. I BELIEVE IT IS COMING FROM THE FUEL PUMP. LEAKS WHEN ENGINE IS RUNNING ONLY. DOES NOT LEAK WHEN AUTO IS NOT RUNNING.

MY VAN ALONG WITH MANY MANY OTHERS SHUTS OFF AFTER REFUELING SPUTTERS RUNS LIKE GARBAGE ALMOST CAUSING ME TO GET INTO A ACCIDENT PULLING OUT OF A GAS STATION ON A ROTARY TODAY

FACTORY FUEL PUMP IS CRACKED, WRIGHT ON THE CONNECTION TO THE FUEL LINE ,ITS A HAIR LINE CRACK,

HAVE FUEL SMELL AT BACK MIDDLE OF VAN, FOUND FUEL LEAKING AT MIDDLE OF FUEL TANK, REPLACED FUEL LINE CONNECTED TO FUEL PUMP OUTPUT CONNECTOR. DID NOT STOP FUEL LEAK, FOUND CRACKED FUEL PUMP AT THE OUTPUT AREA. LEAKS AS LONG AS THE HIGH PRESSURE SIDE OF FUEL PUMP IS PRESSURIZED.

NOTICED GASOLINE SMELL EVERY TIME I STOP/PARK CAR & GET OUT. AFTER FEW WEEKS, CHECKED UNDERNEATH VAN & SAW GAS SLOWLY DRIPPING FROM ABOUT MIDDLE OF GAS TANK. IT WAS RUNNING DOWN THE SIDE FROMN THE TOP OF TANK. STOPPED DRIPPIONG AFTER STOPPED FOR FEW MINUTES, BUT FOUND OUT THAT WHILE VAN WAS RUNNING IT DRIPPED CONSTANTLY. GOOGLED THIS PROBLEM & OTHER ARE HAVING SAME PROBLEM WITH CRACKS IN FUEL PUMP. THIS COULD BE A SERIOUS PROBLEM WITH A SPARK/HOT EXHAUST PIPE/MUFFLER CLOSE BY.

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.

CAR WILL STALL A COUPLE OF TIMES AFTER FILLING UP TANK PROBABLY WILL GO AWAY AFTER DRIVING A COUPLE OF BLOCKS

EVERYTIME THE VAN IS REFUELED, IT WILL STALL ON ACCELERATION. THIS OCCURS FOR THE FIRST FEW MINUTES AFTER REFUEL AND THEN THE VAN RETURNS TO NORMAL OPERATION. THE PROBLEM IS THE FAILURE USUALLY OCCURS WHEN PULL OUT ON THE ROAD BECAUSE THAT IS THE FIRST POINT OF ACCELERATION.

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.

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.

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. THE NEW FUEL PUMP HAS CURRENTLY BEEN ORDERED AND I WILL REPLACE IT FIRST THING IN THE MORNING. THE MILEAGE ON THE VAN IS AT AROUND 137,000 MILES. THIS JUST SEEMS TO BE PRETTY IMPORTANT AS IT'S LEAKING FUEL WHICH IS A POTENTIAL FIRE HAZARD.

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. THIS IS AN EXTREMELY DANGEROUS SITUATION; IT IS JUST A MATTER OF TIME BEFORE SOMEONE GETS KILLED. THERE SHOULD BE AN ALERT AND A RECALL TO CORRECT THIS PROBLEM. UPDATED 9/25/15 *LN

VAN STALLS AFTER FUELING. EVERY TIME YOU FILL UP THE VAN, THE VAN WILL STALL FOR NO REASON. IT WILL RESTART WITHIN A MINUTE OR 2. IT WILL THEN HAVE NO PROBLEMS UNTIL THE NEXT FILL UP. READING REPORTS ON THE WEB, THIS IS HAPPENING ON ALL DODGE AND CHRYSLER VEHICLES EVEN CAUSING SOME TO STALL ON TRAIN TRACKS. NEVER HAD A PROBLEM WITH THE VAN UNTIL I HIT AROUND 100K MILES. ALL OTHER REPORTS ON THE WEB ARE IDENTICAL. CHRYSLER DODGE SHOULD RECALL BEFORE SOMEONE DIES

TL* THE CONTACT OWNS A 2005 DODGE GRAND CARAVAN. THE CONTACT STATED THAT THE FUEL TANK WAS CRACKED AND CAUSED FUEL TO LEAK OUTSIDE OF THE VEHICLE. AS A RESULT, THERE WAS A STRONG FUEL ODOR INSIDE AND OUTSIDE THE VEHICLE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT THERE WAS A HAIRLINE FRACTURE THAT NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 132,000.

VEHICLE STALLED OUT AT THE STOPLIGHT AFTER I HAD FILLED UP THE GAS TANK. I TOOK THE VAN INTO THE DODGE DEALERSHIP AND WAS TOLD THAT I NEEDED TO REPLACE THE WHOLE GAS TANK. *TR

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. THE EXHAUST MANIFOLD, CATALYTIC CONVERTER, UPSTREAM AND DOWNSTREAM O2 SENSORS HAVE ALL BEEN REPLACED WITH OEM/MANUFACTURER STANDARD PARTS.

I HAD NOTICED THE SMELL OF GASOLINE OUTSIDE OF MY CAR A WEEK OR SO BEFORE. MY HUSBAND AND I WENT TO THE GAS STATION TO FILL UP MY TANK. WE PULLED OUT ON TO A MAJOR ROAD WITH TRAFFIC. THE CAR BEGAN JERKING AND TRYING TO STALL. AFTER A FEW MINUTES IT WAS FINE. YESTERDAY, I GOT GAS AGAIN AND PULLED OUT WITH MY KIDS IN THE CAR. THE CAR STARTED DOING THE SAME THING. THERE HAVE BEEN MULTIPLE REPORTS OF THIS HAPPENING. PLEASE HELP BEFORE SOMEONE GETS KILLED! *TR

ON THREE SEPARATE OCCASIONS, THE VEHICLE STALLED AFTER REFUELING. ONE INSTANCE OCCURRED JUST AFTER MERGING ONTO A FREEWAY AFTER REFUELING. THE OTHER TWO INSTANCES OCCURRED IN THE PARKING LOT OF THE FUELING STATION AFTER REFUELING.