2004 Dodge Grand Caravan Fuel system Problems
- Complaints
- 36about this part
- Share
- 31%of 116 total for the year
- Median mileage
- 100,000miles
- Trend
- StableComplaints filed in the last 3 full calendar years are within 25% of the 3 years before.
NHTSA recorded 36 complaints about the fuel system of the 2004 Dodge Grand Caravan, 31% of the 116 complaints for this model year. Where a mileage was given, the median is 100,000 miles.
Example complaints
Selected from NHTSA records; personal details are removed. They are consumer reports, not findings.
“After filling the gas tank, within a few miles the vehicle will stall. Dodge already has extended the warranty on the fuel tank of vehicle built after september 2003 but mine was built august 5 2003 so it is outside their window. This is a very dangerous issue because it has happened to me on the highway at 55 miles an hour and I then have no power and need to get out of the way of traffic that is going to run me over.”
NHTSA complaint #10924275, filed 2016-11, 115,000 miles“After filling my '04 Grand Caravan with fuel and attempting to leave the pump my caravan shuts off. This has been on an ongoing issue for over 2 years. After several repair attempts I was told today that the vapor separator valve located on top of the gas tank is faulty. A valve that Dodge does not make available for repair. The only fix that is offered is to replace the entire tank of which I was told today would be $1600.”
NHTSA complaint #10683697, filed 2015-02, 150,000 miles“Our 2004 Dodge Grand Caravan will stall out driving down the road if you fill the gas tank until the gas pump nozzles stops automatically. The only way to stop this is to replace the gas tank because of a bad valve in the top of the tank in the emissions system. I found this information on line. It has done it several times and we now under fill the tank which is not easy to do.”
NHTSA complaint #10394063, filed 2011-04, 112,000 miles“Every time I fill my tank (I do not top off), within a few minutes of leaving the station, the van dies. It normally re-starts, but it takes quite a lot of gas pedal pumping. This is dangerous when it happens in the middle of an intersection. I had the fuel pump and filter replaced and that did not solve the problem. Now I understand that the valve on top of the tank is at fault, but you have to replace the entire tank. This is a design flaw and needs to be corrected.”
NHTSA complaint #10716797, filed 2015-05, 109,000 miles“Every time we fill the fuel tank the caravan cuts off and rides very rough. The recall on the Dodge caravan was on vans build starting on 09/01/2003 my caravan was built on 09/29/2013.”
NHTSA complaint #10824863, filed 2016-02, 150,000 milesRelated service bulletins
- 10219763Jan 15, 2016Extended Warranty on the Fuel Tank/Vapor Cannister
- 10209634Jan 15, 2016Extended Warranty on the Fuel Tank/Vapor Cannister
- 10076430Jan 15, 2016(x60) fuel tank/vapor canister - 2004-2005-town and country (rs) and caravan/grand caravan (rs)
Fuel system: other model years
| Year | Complaints | Share of year |
|---|---|---|
| 2020 | 1 | 5% |
| 2019 | 14 | 6% |
| 2018 | 8 | 3% |
| 2017 | 14 | 3% |
| 2016 | 26 | 3% |
| 2015 | 6 | 2% |
| 2014 | 11 | 3% |
| 2013 | 41 | 9% |
| 2012 | 74 | 13% |
| 2011 | 137 | 26% |
| 2010 | 23 | 3% |
| 2009 | 12 | 2% |
| 2008 | 15 | 1% |
| 2007 | 49 | 27% |
| 2006 | 31 | 11% |
| 2005 | 64 | 6% |
| 2004 | 36 | 31% |
| 2003 | 10 | 5% |
| 2002 | 21 | 7% |
| 2001 | 19 | 6% |
| 2000 | 23 | 5% |
| 1999 | 14 | 3% |
| 1998 | 25 | 4% |
| 1997 | 38 | 7% |
| 1996 | 181 | 16% |
| 1995 | 6 | 6% |
| 1994 | 10 | 5% |
| 1993 | 11 | 4% |
| 1992 | 5 | 2% |
| 1991 | 16 | 12% |
| 1990 | 11 | 20% |
| 1989 | 1 | 4% |
| 1988 | 1 | 10% |
Other parts of the 2004 Dodge Grand Caravan
15 complaintsEngine cooling
14 complaintsElectrical system
13 complaintsSteering
13 complaintsLatches, locks and linkages
9 complaintsEngine
6 complaintsAir bags
5 complaintsExterior lighting
4 complaintsBody and structure
4 complaintsEquipment
3 complaintsTires
3 complaintsTransmission and drivetrain
3 complaints
← All problems reported for the 2004 Dodge Grand Caravan
About this data. Data from NHTSA (ODI) complaints, recalls, TSBs and investigations, updated Oct 31, 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