2004 Dodge Caravan Fuel system Problems
- Complaints
- 18about this part
- Share
- 28%of 65 total for the year
- Median mileage
- 73,500miles
- Trend
- StableComplaints filed in the last 3 full calendar years are within 25% of the 3 years before.
NHTSA recorded 18 complaints about the fuel system of the 2004 Dodge Caravan, 28% of the 65 complaints for this model year. Where a mileage was given, the median is 73,500 miles.
Example complaints
Selected from NHTSA records; personal details are removed. They are consumer reports, not findings.
“I purchased my vehicle in the fall of 2013 and am starting to come to the conclusion that every time I fill my gas tank up my vehicle shuts off! Today I filled up my gas tank. My children were in the back seat and when I pulled out into the highway the van shut off and the steering wheel locked up! I had no control over the vehicle. This seems to be a common problem with these vans and something needs to be done before someone gets hurt! I can't fill my gas tank up because of this issue.”
NHTSA complaint #10695523, filed 2015-03, 118,000 miles“Not 100% but probably 40% - 60% of the time I refuel - especially a full tank - the car will tend to hesitate and stall within the first 90 seconds of getting back on the road. Seems like it has not done it a lot lately but I just had some work done by the local Dodge dealer including new wires and plugs. When I left the dealership it ran fine. I put in probably 3/4 tank of gas in it and it began hesitating and stalling worse than it had in some time. The weather was also quite a bit cooler than it had been in 6 months. …”
NHTSA complaint #10632928, filed 2014-09, 39,000 miles“This complaint is for a 2004 Dodge Caravan the problem occurs when the gas tank is filled. The vehicle stalls and runs rough for several miles and sometimes many more. I believe the defect is the liquid/vapor valve built into the top of the fuel tank. It fails and allows fuel into the evac canister and vapor lines which could explode or cause a fire as they are not designed to hold gasoline. Chrysler seems to care less. I'm sure when people start to burn to death something will be done. Thank you”
NHTSA complaint #10372112, filed 2010-12, 70,000 miles“My family began noticing a gas smell several months ago. It was more noticeable when exiting the vehicle and when in a closed garage. At first I thought it might be from some gas spill on fueling. I did not see any leaks on the ground or in the engine area. I just had the van serviced at the dealer and was told there was a gas leak. Upon closer inspection it appears there is a very slow leak (seepage) coming at the connection off the fuel pump and fuel line. This looks like a twist-off connection. The dealer told me it would cost $96/hr to pinpoint and diagnosis the exact problem. …”
NHTSA complaint #10499573, filed 2013-02, 51,000 miles“I was traveling on the freeway at speed or slightly above when my gas light went on and the van started to sputter. Then the engine light went on and my speed decreased to appx 40 MPH. I immediately got to the side of the road during rush hour and cars speeding by me. It was extremely dangerous and scary. A police officer stopped to assist me and try to get me towed. I made it to the next gas station. I added gas and oil. However, due to the fact that it was shaking and not able to make it above 40 MPH, I decided to have it towed home until a decision could be made about what to do. …”
NHTSA complaint #10552485, filed 2013-11, 172,874 milesRelated service bulletins
- 10219763Jan 15, 2016Extended Warranty on the Fuel Tank/Vapor Cannister
- 10218069Jan 15, 2016This bulletin involves replacing the fuel tank and vapor canister.
- 10209634Jan 15, 2016Extended Warranty on the Fuel Tank/Vapor Cannister
- 10119629Jan 15, 2016Engine Stall Immediately Following Fuel Tank Fill-Up (X60 Warranty Extension) This bulletin involves replacing the fuel tank and vapor canister. Some customers may experience an…
- 10076430Jan 15, 2016(x60) fuel tank/vapor canister - 2004-2005-town and country (rs) and caravan/grand caravan (rs)
- 10021668Apr 5, 2007Cleaning procedure for the mechanical throttle body.
Fuel system: other model years
| Year | Complaints | Share of year |
|---|---|---|
| 2014 | 1 | 5% |
| 2013 | 1 | 3% |
| 2012 | 6 | 7% |
| 2011 | 14 | 18% |
| 2010 | 4 | 2% |
| 2009 | 1 | 1% |
| 2008 | 6 | 2% |
| 2007 | 16 | 20% |
| 2006 | 15 | 9% |
| 2005 | 37 | 7% |
| 2004 | 18 | 28% |
| 2003 | 13 | 7% |
| 2002 | 9 | 4% |
| 2001 | 12 | 5% |
| 2000 | 15 | 3% |
| 1999 | 20 | 4% |
| 1998 | 41 | 7% |
| 1997 | 60 | 8% |
| 1996 | 222 | 16% |
| 1995 | 24 | 5% |
| 1994 | 22 | 3% |
| 1993 | 15 | 2% |
| 1992 | 19 | 2% |
| 1991 | 25 | 4% |
| 1990 | 11 | 4% |
| 1989 | 3 | 2% |
| 1988 | 6 | 6% |
| 1987 | 1 | 1% |
| 1986 | 2 | 4% |
| 1985 | 2 | 4% |
| 1984 | 1 | 6% |
Other parts of the 2004 Dodge Caravan
8 complaintsElectrical system
8 complaintsSteering
6 complaintsAir bags
4 complaintsEngine cooling
4 complaintsEquipment
4 complaintsOther or unknown
4 complaintsBody and structure
4 complaintsTransmission and drivetrain
4 complaintsEngine
3 complaintsExterior lighting
3 complaintsSeats
3 complaints
← All problems reported for the 2004 Dodge Caravan
About this data. Data from NHTSA (ODI) complaints, recalls, TSBs and investigations, updated Oct 30, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.
To check a specific vehicle for open recalls, use its VIN at nhtsa.gov/recalls. Methodology