2006 Dodge Grand Caravan Fuel System Problems

EVERY TIME I FILL UP THE THE VAN DIES OR RUNS POORLY FOR A FEW MINUTES. I IS ALWAY IN TRAFFIC WHEN IT DIES. I FILL UP AND PULL OUT INTO THE ROAD AND IT DIES. STARTS BACK AT ONCE BUT IT IS VERY DANGEROUS

VEHICLE OFTEN STALLS SHORTLY AFTER REFUELING. CAN BE VERY DANGEROUS IF PULL OUT INTO TRAFFIC. HAS HAPPENED AT LEAST A DOZEN TIMES. DOES NOT HAPPEN WITH EVERY FILL-UP, BUT IS BECOMING MORE FREQUENT.

WE PURCHASED VAN NEW FROM DODGE DEALER IN SEPTEMBER OF 2006. ABOUT 5 MONTHS AGO MY WIFE (NORMALLY DRIVES) STALLED PULLING TOWARD AN INTERSECTION SHORTLY AFTER SHE DROVE FROM FILLING THE GAS TANK. THE VAN RUNS FINE OTHERWISE AND NOW HAS ABOUT 112K MILES. THIS HAPPENED TO HER A FEW MORE TIMES (VERY STRESSFUL LOSING POWER STEERING AND BRAKES). THEREFORE, ONE FILL-UP TO CHECK IT I DROVE THE CAR AND IT DID THE SAME A COUPLE MINUTES AFTER FILL-UP DRIVING 1/4 MILE SLOWLY IN NEARBY HOME DEPOT PARKING LOT (AFRAID I WOULD HIT SOMEONE TRYING TO TURN (SIMILAR CONDITIONS AS MY WIFE HAD). THE VAN WILL RESTART AFTER TRYING A COUPLE OF TIMES AND THEN RUN FINE FOR THE REST OF THE TANK. WE HAVE BEEN FORCED TO STOP FILLING THE TANK ABOVE 3/4, AN INCONVENIENCE TO PLAN FOR BUT SEEMS TO ELIMINATE THAT PROBLEM; BUT I AM NOT SURE HOW MUCH LONGER THAT WILL WORK. IN DOING RESEARCH I UNDERSTAND OTHER DODGE VAN OWNERS IN THAT YEAR RANGE HAVE HAD THIS PROBLEM. APPARENTLY, DUE TO THE DESIGN OF THE VALVE THAT IS FAILING THE ENTIRE GAS TANK MUST ALSO BE REPLACED WHICH IS VERY COSTLY. I FEEL THAT CHRYSLER USED A VERY POOR DESIGN OR PART WHERE IF ONLY THE VALVE FAILS THAT THE ENTIRE GAS TANK MUST BE REPLACED. THE VAN RUNS FINE, WE LIKE THE VAN AND WERE PLANNING TO DRIVE IT MANY MORE MILES BUT AT THIS POINT THE COSTLY REPAIR INVOLVED IS A GOOD PORTION OF THE VEHICLE VALUE. I THINK THAT CHRYSLER SHOULD HELP US IN REPAIRING THIS ISSUE. IT IS OBVIOUSLY A SAFETY ISSUE WHEN DRIVING THE CAR, AND A DESIGN FLAW IN MY OPINION IN THAT FAILURE OF A SMALL COMPONENT REQUIRES THE WHOLE GAS TANK SYSTEM TO BE REPLACED. PLEASE LET US KNOW CHRYSLER'S POSITION ON THIS ISSUE. WE REALIZE THAT THE VEHICLE IS OUT OF CHRYSLER'S WARRANTY BUT FEEL THIS IS SOMETHING THAT SHOULD HAVE BEEN RECTIFIED WHEN THE ISSUE BECAME KNOWN A NUMBER OF YEARS AGO. THANKS IN ADVANCE

UNABLE TO FILL WITH GAS AT SERVICE STATION (EVAPORATIVE SISTEM). THE NOZZLE KEPT SHUTTING OFF EVEN THOUGH THE TANK WAS NEARLY EMPTY.

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.

ENGINE ROUGH IDLE AFTER FUELING AND OCCASIONALLY STALLS ON ROAD

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. THE VALVE CANNOT BE REPLACED WITHOUT REPLACING THE ENTIRE GAS TANK. THE VALVE CANNOT BE PURCHASED SEPARATELY. BECAUSE THE VALVE IS CONSIDERED AN EMISSIONS PROBLEM AND THE GAS TANK IS NOT, SOME WARRANTY COMPANIES WILL NOT COVER THE REPLACEMENT. THIS PLACES THE CONSUMER AT RISK BECAUSE THE HIGH COST MAY NOT BE FEASIBLE AND THE CONSUMER MAY OPT TO CONTINUE TO DEAL WITH THE VEHICLE STALLING IN LIEU OF REPAIRS. IF THIS IS A COMMON PROBLEM WITH THESE VEHICLES, CHRYSLER SHOULD EITHER RECALL OR ALLOW THE VALVE TO BE PURCHASED SEPARATELY.

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. AS SOON AS I FILL IT AND DRIVE OFF, IT STALLS, ONCE IT'S DRIVEN A WHILE, IT WORKS FINE. I THINK THE DEALERSHIP IS WRONG TO COVER UP THE REAL PROBLEM.

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.

POST REFUELING STALLS. WHILE GOING ON LONG TRIPS, AFTER REFUELING IN THE REST AREAS, THE MINIVAN STALLS WHILE ENTERING THE HIGHWAY CAUSING ME TO PANIC WHILE AVOIDING HIGH SPEED TRAFFIC GOING BY. THIS HAPPEN MANY TIME DURING A TRIP TO FLORIDA FROM INDIANA.

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 *BF *JS

I WAS PICKING UP A MACHINE IN GEORGIA, AND I HAD TO STOP AND GET GAS. I FILLED UP WITH GAS DROVE ONTO THE TURNPIKE AND THE CAR STALLED AND A TRUCK ALMOST HIT MY CAR AS MY CAR WAS COASTING TO GET IT OFF THE HIGHWAY. HE HIT HIS BRAKES AND SQUEALED UP TO MY VEHICLE. THIS SITUATION COULD KILL SOMEONE AND I READ HUNDREDS OF COMPLAINTS FROM PEOPLE ONLINE. THIS HAPPENS ON EVERY FILL UP SINCE. *DT

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. *TR

TL* THE CONTACT OWNS A 2006 DODGE GRAND CARAVAN. THE CONTACT STATED WHILE DRIVING APPROXIMATELY 30 MPH IMMEDIATELY AFTER REFUELING, THE VEHICLE SUDDENLY STALLED. AFTER RESTARTING THE VEHICLE RESUMED NORMAL FUNCTION. THE CONTACT INDICATED THAT THE DEFECT HAD OCCURRED ON TWO SEPARATE OCCASIONS AND THE DEFECT ONLY OCCURRED AFTER FILLING THE FUEL TANK. THE VEHICLE WAS TAKEN TO THE DEALER. THE TECHNICIAN DIAGNOSED THAT THE ROLL OVER VALVE INSIDE THE FUEL TANK WAS DEFECTIVE. THE VEHICLE WAS CURRENTLY BEING REPAIRED BY THE DEALER. THE MANUFACTURER WAS NOTIFIED OF THE DEFECT. THE FAILURE MILEAGE WAS 143,000.

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 1:00PM 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. *TR

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. THE CONTACT STATED THAT WHEN REFUELING TO A HALF OR FULL FUEL TANK, THE VEHICLE STALLED. THE FAILURE OCCURRED ON NUMEROUS OCCASIONS. ADDITIONALLY, THE CONTACT STATED THAT THE KEY FAILED TO TURN IN ORDER TO START THE VEHICLE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC, WHO DIAGNOSED THAT A SENSOR FAILED WITHIN THE FUEL TANK AND THE FUEL TANK NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 50,000.

FILLED FUEL TANK RIGHT OFF I24 IN TN. CAR STALLED ON ENTRANCE RAMP TO HIGHWAY. DRIFTED TO SIDE AND ENGINE RESTARTED QUICKLY. THIS NOW HAPPENS ALMOST EVERY TIME THE TANK IS FILLED. AROUND TOWN I CAN COPE BY NOT FILLING THE TANK, BUT VERY INCONVENIENT AND VERY DANGEROUS ON TRIPS ESPECIALLY ON HIGHWAYS. WE ARE NOT TALKING ABOUT OVERFILLING THE TANK, BUT JUST FILLING TO POINT WHEN PUMP SHUTS OFF. WHEN ENGINE STALLS, NOT ONLY IS THERE AN IMMEDIATE LOSS OF MOMENTUM, THE POWER STEERING SYSTEM QUITS, BUT THE BRAKES BECOME USELESS. EVERY TIME THIS HAPPENS, I JUST WAIT FOR SOMEONE BEHIND ME TO NOT SLOW DOWN IN TIME AND REAR-END ME. LUCKILY, I HAVE NOT BEEN IN THE FAST OR MIDDLE LANE WHEN IT STALLS, BECAUSE OF POSSIBLY NOT BEING ABLE TO GET TO THE SHOULDER TO RESTART IT. I AM ALSO PARANOID THAT IF I TRY TO MESS WITH PUTTING IT INTO NEUTRAL AND FOOLING AROUND WITH THE KEY, I WILL BECOME A VERY DISTRACTED DRIVER. CHRYSLER'S ANSWER IS TO REPLACE FUEL TANK AT A COST OF $1200. IF I COULD AFFORD THAT THEN I WOULDN'T BE DRIVING A 2006 AUTOMOBILE. *TR

AFTER FILLING THE GAS TANK WITH GASOLINE, THE CAR WILL OFTEN STALL TEMPORARILY AFTER TRAVELING APPROXIMATELY 1/4 MILE. THIS HAS HAPPENED NUMEROUS TIMES, BUT THE CAR HAS ALWAYS RESTARTED. I THOUGHT THAT I WAS USING A POOR BRAND OF GASOLINE, BUT I JUST RECEIVED NOTICE OF A RECALL FOR STICKING FUEL FILL VALVE ON MY OTHER VEHICLE, WHICH HAS NEVER (TO MY KNOWLEDGE) EXPERIENCED THIS PROBLEM. *TR

VAN STALLS A FEW MINUTES AFTER RE-FUELING TANK TO FULL LEVEL. TANK IS NOT TOPPED OFF BEYOND WHAT AUTO SHUT-OFF NOZZLE AT STATION ALLOWS. STALLING QUITE OFTEN HAPPENS WHEN DRIVING BACK ONTO MAIN STREETS FROM GAS STATION. ALL POWER BRAKING AND STEERING IS LOST WHEN THIS HAPPENS WHICH PRESENTS A VERY DANGEROUS SITUATION ESPECIALLY IN HEAVIER TRAFFIC CONDITIONS. VAN MUST BE COMPLETELY STOPPED AND RESTARTED. ONCE RESTARTED, VEHICLE DOES NOT EXHIBIT PROBLEM UNTIL NEXT FILL UP. *TR