2004 Dodge Grand Caravan — Known Issues & Recalls

Your fuel pump has developed hairline cracks where it connects to the fuel line, causing a strong fuel smell and fuel vapors around the vehicle. This creates a potential fire hazard since the leaking fuel is located near your hot muffler. The fuel pump will need to be replaced to fix this problem.

Your van stalls within a few miles after you fill up the gas tank, which has happened to you on the highway at 55 mph and forced you to pull over quickly. Dodge extended the warranty on fuel tanks for vans built after September 2003, but your August 2003 van falls outside that coverage window. The fix will likely involve inspecting or replacing the fuel tank and related fuel system components.

Your vehicle has stalled unexpectedly while driving multiple times — once in a busy intersection and once on the highway at 60+ mph, forcing you to coast with no power steering. Additionally, your car stalls almost every time you fill up the gas tank and leave the station, though it restarts after about a minute. This pattern suggests a fuel system issue that may need diagnostic testing and potentially fuel pump or fuel pressure regulator replacement.

Every time you fill up the fuel tank, your Caravan stalls and runs very roughly afterward. You've noted that a recall was issued for Caravans built starting September 1, 2003, but your vehicle was built on September 29, 2013, which may fall outside the original recall window.

After you fill up your gas tank, your van stalls without warning and is hard to restart. The problem happened multiple times, though the vehicle eventually did start again each time. The issue wasn't diagnosed or fixed. The fix will likely involve inspecting the fuel system components, including the fuel pump, fuel injectors, and fuel pressure regulator.

Your engine stalls out about 10-15 seconds after you fill up the gas tank, typically when you're turning onto the highway. This has been happening intermittently for a couple of years. The issue likely involves the fuel system's ability to properly regulate pressure or vent when the tank is full.

Your car stalls out shortly after you fill up the gas tank at a gas station. The issue is reportedly caused by a faulty check valve in the fuel system, and the repair requires replacing the entire fuel tank.

After filling up your gas tank, the check engine light comes on and indicates an emissions leak. This causes fuel vapors to build up inside your van after each refueling. If you fill the tank completely, your engine may stutter and sometimes stall shortly after fueling. The issue likely involves a faulty gas cap, fuel vapor canister, or related emissions system component that needs inspection and replacement.

Your van stalls immediately after refueling at gas stations, creating a dangerous situation on busy roads. This happens consistently when you fill up, though the van restarts and runs normally afterward. The issue appears to be related to the fuel tank or fuel sensor and may require diagnostic testing and potential replacement of fuel system components.

Your van stalls shortly after you fill up the gas tank at the station. While it usually restarts after pumping the gas pedal repeatedly, this is dangerous when it happens in traffic. You've already had the fuel pump and filter replaced without solving the issue, and the problem appears to be caused by a faulty valve on top of the fuel tank that requires replacing the entire tank. The repair will likely involve draining and removing the fuel tank to access or replace the tank vent valve.

Your car shuts off and stops running shortly after you fill up the gas tank, and this has happened multiple times while you're driving in traffic. This is a dangerous situation since the engine suddenly dies while you're on the road. The issue likely involves the fuel system's ability to properly handle a full tank, and may require inspection of the fuel vapor canister or related fuel pressure components.

Your van shuts off immediately after you fill up the gas tank, and this problem has been happening for over 2 years. The issue is a faulty vapor separator valve on top of the fuel tank that Dodge no longer sells as a separate part. The only repair option available is to replace the entire fuel tank, which costs around $1,600.

Your fuel pump has developed hairline cracks in multiple locations and is leaking gasoline. The damage appears to have been there for a while before you noticed it. This seems to be a recurring problem affecting multiple 2004 Dodge Grand Caravan models. Fixing this will likely require replacing the fuel pump assembly.

Your vehicle was hit from behind by another car, but the airbags didn't deploy even though the airbag warning light came on. You hit your face on the steering wheel and were injured seriously enough to require hospitalization. The dealer said your vehicle wasn't part of a recall for this airbag failure.

Your passenger side airbag deployed while you were driving, even though no one was sitting in the passenger seat and there was no accident or impact. This is a serious safety concern because airbags should only deploy during a collision or impact event.

Your sliding door's power lock actuator has failed, which prevents the door from being unlocked manually. This is a serious safety problem because rear passengers cannot exit through the sliding doors in an emergency and would have to climb over seats to escape. The fix would likely involve replacing the door lock actuator mechanism to restore manual unlocking capability.

Your engine stumbles or shuts off shortly after refueling, sometimes at highway speeds, forcing you to pull over. The engine typically restarts and runs normally until the next fill-up. Your mechanic identified a faulty valve inside the fuel tank that cannot be replaced as a separate part. This stalling hazard has created dangerous traffic situations and you've had to change your driving habits to avoid highway speeds immediately after refueling.

Your engine has been overheating without warning, forcing you to pull over multiple times to let it cool down. When you replaced the thermostat, plastic pieces came out of the engine, suggesting internal damage from prolonged overheating over the past 4 years. The overheating issue likely stems from a failed thermostat or coolant system failure that needs diagnosis and repair of the cooling system components.

While driving at 45 mph, your temperature gauge climbed into the red zone, suggesting your engine cooling system wasn't working properly. You also noticed a strong fuel smell coming into the cabin. A mechanic diagnosed that your fuel pump and carbon filter needed replacement to fix these issues.

Every time you fill up your gas tank, the engine runs roughly, hesitates, or stalls when you pull out of the gas station—even if you only added 5 gallons to a half-full tank. This has happened in the middle of intersections while turning, creating a safety risk. The issue appears to be related to a valve above the tank that cannot be replaced separately, requiring replacement of the entire fuel tank.