2004 Dodge Grand Caravan

WHILE MAKING LEFT THE VEHICLE STALLED WHILE IN MOTION IN THE MIDDLE OF MAJOR INTERSECTION. AFTER A 20 OR SO SECONDS, THE VEHICLE ENGINE TURNED ON. ANOTHER INCIDENT, APPROXIMATELY A YEAR AGO, WHILE TRAVELING 60+ MILES ON MAJOR INTERSTATE, THE VEHICLE AGAIN SHUT DOWN WHILE IN MOTION. I HAD TO COAST THE VEHICLE, WITH LOSS OF POWER, TO MEDIAN ON THE INTERSTATE. AFTER ABOUT A MINUTE OR SO, THE VEHICLE TURNED ON. ALWAYS UPON FILLING THE GAS TANK, THE VEHICLE STALLS WHILE EXITING THE GAS STATION OR SHORTLY THEREAFTER. AFTER A MINUTE, THE VEHICLE IS ABLE TO TURN BACK ON. *TR

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. *TR

AFTER TAKING ON GAS, ENGINE WILL SOMETIMES STUMBLE AND MOST OF THE TIME QUIT RUNNING. TRIED NOT OVER FILLING IT AND IT STILL WILL JUST DIE SOMETIME AFTER TAKING ON GAS. ON TWO OCCASIONS, IT DID THIS AFTER HITTING HIGHWAY SPEEDS. IT WOULD SUDDENLY LOSE POWER AND YOU HAD TO PULL OFF THE ROAD. IT WOULD NORMALLY START BACK UP AND HAVE NO MORE PROBLEMS UNTIL NEXT FILL UP. BECAUSE OF THIS, WE DON'T FILL UP AND HIT THE ROAD. WE DRIVE AROUND BEFORE DRIVING AT HIGHWAY SPEEDS. ONCE, IT DIED IN FRONT OF SEVERAL CARS AND A BIG TRUCK HAD TO BRAKE HARD AND SWERVE OFF THE ROAD. SO FAR, THERE HAS NOT BEEN ANY KNOWN ACCIDENTS BUT FEEL IT IS A MATTER OF TIME BEFORE SOMEONE GETS HURT. THE MECHANIC SAID IT WAS SOMETHING WRONG WITH A VALVE IN GAS TANK AND THAT YOU CAN'T BUY THE PART. WE DON'T LOAN OUR VAN TO THE KIDS ANYMORE SINCE MY OLDEST DAUGHTER ALMOST CAUSED A WRECK AND ALMOST GOT HIT WHEN THE VAN LOST POWER. *TR

FOR THE PAST FOUR YEARS OR SO, ALMOST EVERY TIME AFTER FILLING UP THE GAS TANK, THE 2004 DODGE GRAND CARAVAN ANNIVERSARY EDITION STALLS. I CAN BE JUST PULLING AWAY FROM THE PUMP WHEN IT HAPPENS, OR STOPPED AT A STOP LIGHT WITHIN A FEW MINUTES FROM LEAVING THE GAS STATION. YOU CAN FEEL THE CAR 'JUMP' LIKE SOMEONE IS PRESSING THE GAS PEDAL QUICKLY AND IT JERKS THE VAN A BIT FORWARD. THEN IT STALLS. IT TAKES A FEW TURNS OF THE KEY AND PRESSING THE GAS PEDAL VERY QUICKLY AND FORCEFULLY TO GET IT STARTED AGAIN. I HAVE GOTTEN INTO THE HABIT OF DRIVING THE VAN AROUND A PARKING LOT FOR A FEW MINUTES UNTIL IT FEELS BACK TO NORMAL BEFORE PULLING OUT INTO TRAFFIC, AS I'M CONCERNED IT WILL STALL OUT IN THE MIDDLE OF TRAFFIC. THIS ONLY HAPPENS RIGHT AFTER FILLING UP THE GAS TANK. IT CONCERNS ME NOW MORE THAN EVER SINCE MY SON IS LEARNING HOW TO DRIVE AND I WANT HIM TO BE SAFE. *TR

ENGINE STARTED MISSING, VIBRATIONS FROM ENGINE. DIAGNOSIS ELECTRICAL FAULT. WIRING HARNESS BRITTLE FORM HARNESS BEING PLACED ON, OVER AND NEXT, SNAKED AROUND EXHAUST MANIFOLD, CAUSING PREMATURE WIRING FAILURE. FUEL INJECTOR WIRING HARNESS UNSHIELDED IN SIDE OF INTAKE MANIFOLD / PLENUM. WIRING HARNESS POORLY SHIELDED. THIS IS A DELIBERATE, INTENTIONAL DESIGN / ENGINEERING TO SNAKE WIRING HARNESS AROUND EXHAUST MANIFOLD. CAUSING WIRING HARNESS FAILURE. USING SUB-STANDARD WIRING COMPONENTS AND NOT USING SHIELDING TO CAUSE PRE-MATURE FAILURE. INSTALLING PCM (COMPUTER) IN WHEEL WELL FOR PRE-MATURE FAILURE EXPOSED TO SALT, ROAD DEBRIS, WATER, ETC. PCM INSTALLED IN OPEN AREA OF VEHICLE PRONE TO FAILURE. CONSEQUENTIAL SAFETY ISSUES. *TR

TL* THE CONTACT OWNS A 2004 DODGE GRAND CARAVAN. THE CONTACT STATED THAT THE VEHICLE WOULD STALL IMMEDIATELY AFTER REFUELING. THE CONTACT INDICATED THAT THE FAILURE HAD OCCURRED ON MULTIPLE OCCASIONS AND IN SOME INSTANCES THE VEHICLE WOULD STALL UP TO TWO TIMES BEFORE OPERATING AS NORMAL. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE BUT NO SOLUTION WAS OFFERED. THE FAILURE MILEAGE WAS 115,000.

BEGINNING AROUND AUGUST 2012, MY 2004 DODGE GRAND CARAVAN ANNIVERSARY EDITION BEGAN TO SPUTTER AND STALL IF I EVER FILLED THE GAS TANK COMPLETELY. IF I DID NOT CONTINUE TO FEED GAS TO THE ENGINE, THE ENGINE WOULD STALL. AT STOPLIGHTS I WOULD NEED TO PUT THE CAR IN PARK AND REV THE GAS AND THEN SIT IN PARK UNTIL I WAS ABLE TO MOVE. THIS WOULD CONTINUE FOR APPROX 2-3 MILES. IN SUMMER 2013 IT BEGAN HAPPENING EVEN IF THE CAR WAS NOT FILLED TO CAPACITY. REPAIR SHOPS TELL ME IT'S THE TYPE OF GAS OR THERE IS WATER IN THE GAS LINE, BUT MY RESEARCH TELLS ME THIS IS A KNOWN CARAVAN ISSUE. MY REQUESTS FOR REPAIR INVESTIGATIONS ARE NOT TAKEN SERIOUSLY. SO MY SOLUTION IS TO NEVER FILL THE CAR BEYOND 3/4 TANK - SUPER INCONVENIENT. AS A RESULT, THE SPUTTERING DOES NOT HAPPEN AS MUCH ANY MORE, BUT THE SITUATION IS DANGEROUS AND SCARY. I AM JUST WAITING FOR THE ENGINE TO FAIL IN THE MIDDLE OF A BUSY ROAD SIMPLY BECAUSE I'VE GOTTEN FUEL. *TR

MY VAN LEFT SMALL FUEL MARKS IN DRIVEWAY, I INVESTIGATED IT PHYSICALLY AND FOUND FUEL TO BE LEAKING BY FUEL PUMP HOUSING NEAR A FUEL LINE, I ASSUMED IT WAS LEAKING FROM THE O-RINGS ON QUICK DISCONNECT LINE. I REPLACED O-RINGS AND THE PROBLEM STILL EXISTS. I GOOGLED THE ISSUE AND TO MY SURPRISE THERE ARE MANY SIMILAR ISSUES, PEOPLE EXPLAINING HOW THEIR VEHICLES WHERE LEAKING IN THE SAME LOCATION. AFTER BROWSING I FOUND A WEBSITE WHERE THERE WAS A PICTURE SHOWING FRACTURES ON THE HOUSING NEAR THE FUEL LINE THAT I HAD WORKED ON. SURE ENOUGH I RECHECKED MY VEHICLE AND THERE WERE THE FRACTURES. LEAKING FUEL. I JUST WANTED TO POST THIS ON THIS WEBSITE TO INFORM OTHER OWNERS, THAT IF THEY SMELL FUEL FROM THEIR VAN, THEY SHOULD GET THIS ISSUE CHECKED ASAP. THIS IS A REAL HAZARD, AND COULD BE REALLY DANGEROUS. *TR