2004 Dodge Grand Caravan Engine Problems

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.

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

TL* THE CONTACT OWNS A 2004 DODGE GRAND CARAVAN. AFTER REFUELING THE VEHICLE AND DRIVING AT VARIOUS SPEEDS, THE ENGINE STALLED. THE CONTACT WAS ABLE TO RESTART THE VEHICLE, BUT THE FAILURE RECURRED ON NUMEROUS OCCASIONS. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO WAS UNABLE TO DIAGNOSE THE CAUSE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS UNKNOWN.

PERIODICALLY, THE ENGINE OF OUR 2004 GRAND CARAVAN SPUTTERS AND DIES WITHOUT WARNING. TYPICALLY THIS HAPPENS RIGHT AFTER FILLING THE GAS TANK. UPON LEAVING THE GAS STATION, THE VAN RUNS NORMALLY FOR A MINUTE OR TWO, THEN CUTS OUT ALL TOGETHER. USUALLY THIS HAPPENS JUST AS WE ARE PULLING OUT OF THE STATION INTO TRAFFIC. ONCE THE VAN IS RE-STARTED, IT RUNS ROUGHLY FOR A MINUTE, THEN QUITE NORMALLY. THIS FIRST OCCURRED IN LATE 2009 AND HAPPENED INFREQUENTLY FOR A TIME. THE OLDER THE VAN BECOMES, THE MORE FREQUENTLY IT HAPPENS - NOW ON ALMOST EVERY FILL-UP. RELATED TO THIS ISSUE, PERIODICALLY AFTER STARTING THE VAN AT HOME, WITH A NEARLY FULL TANK OF GAS, IT RUNS FINE FOR A MINUTE OR TWO, THEN THE ENGINE SEEMS TO GO INTO IDLE AND COMPLETELY FAILS TO RESPOND TO THE GAS PEDAL. TYPICALLY THIS HAPPENS AFTER STOPPING AT A STOP SIGN NEAR HOME. THE ENGINE RUNS, BUT THERE IS NO ACCELERATION. WE DRIFT TO THE SIDE OF THE ROAD, BRAKE TO A STOP, WAIT A MINUTE (SOMETIMES SHIFT TO PARK), THEN TRY THE GAS PEDAL AGAIN. THE VAN WILL RESPOND NORMALLY AT THAT POINT AND RUN FOR THE REST OF THE DAY WITHOUT FURTHER TROUBLE. (THIS SEEMS TO HAPPEN MORE OFTEN WHEN OUTSIDE TEMPERATURES ARE BETWEEN 50 AND 65 DEGREES.) WE HAVE HAD THE VEHICLE EXAMINED A NUMBER OF TIMES BY SEVERAL VERY REPUTABLE AUTO SERVICES AND NONE HAVE BEEN ABLE TO IDENTIFY OR CORRECT THE PROBLEM.

SINCE THIS DATE, AFTER EVERY FILL UP, THE CAR WILL HESITATE, BACKFIRE, AND IN MANY CASES DIE. THE CAR CAN BE RESTARTED, AND THEN WILL OPERATE WITH NO DIFFICULTY. ON ONE OCCURRANCE THE BACKFIRE WAS SO PRONOUNCED THAT IT BLEW THE AIR CLEANER OFF, BREAKING ALL OF THE MOUNTING CLIPS. THE CAR MUST BE DRIVEN VERY CAREFULLY AFTER A FILL UP DUE TO THIS CONDITION. YOU CANNOT RELY ON GETTING INTO HEAVY TRAFFIC DUE TO THE HESITATION AND FREQUENCY OF THE ENGINE DIE OUT. I HAVE TAKEN THIS CAR IN TO THE DODGE DEALER ON MORE THAN ONE OCCASSION AND THEY CLAIM NO KNOWKLEDGE OF THE ISSUE. I WRITE THIS BECAUSE THERE WAS AN ARTICLE IN THE KENOSHA NEWS, DATED WEDNESDAY MAY 15TH, 2013 WHICH DETAILED 3 CHRYSLER, DODGE BRAND CARS PROBED FOR THIS SAME ISSUE. THEY MENTIONED ONLY V8 ENGINES, BUT I WANT TO LET SOMEONE KNOW THAT THIS ISSUE INCLUDES OTHERS SUCH AS MY 3.3L V6. I AM SURE THAT I AM NOT THE ONLY ONE TO EXPERINECE THIS PROBLEM. *TR

IN JANUARY 2011, I HAD TO REPLACE THE CATALYTIC CONVERTER IN MY VEHICLE AND IT HAS BEEN RUNNING FINE UNTIL NOW. LAST WEEK, MY CHECK ENGINE LIGHT CAME ON AND I MADE A SERVICE APPT. WITH MCKINNEY DODGE IN EASLEY SC TO GET IT CHECKED OUT. I WAS CALLED TODAY (04/02/2013) AND WAS ADVISED THE SAME PART NEEDED TO BE REPLACED AGAIN. THE SERVICE DEPARTMENT ADVISED THE PART ONLY HAD A 12 MONTH WARRANTY. I TOLD HIM THIS WAS UNACCEPTABLE FOR A PART THAT WAS VERY EXPENSIVE TO ONLY HAVE A 12 MONTH WARRANTY. HE PROVIDED THE CHRYSLER CUSTOMER SERVICE # (1-800-992-1997). I CALLED THEM AND THE LADY REVIEWED THE RECORD, AND RESTATED THEY COULD NOT ASSIST, AS IT ONLY HAD A 12 MONTH WARRANTY. THE VEHICLE MILEAGE IS NOW A LITTLE OVER 156,000. I HAVE PUT AROUND 45,000 MILES ON THE CAR SINCE JANUARY 2011. I HAVE HAD THIS VAN FOR YEARS, AND HOW COULD THE ORIGINAL PART ON THE VEHICLE LAST FOR MANY YEARS, AND THEN A REPLACEMENT PART ONLY LAST A LITTLE OVER 2 YEARS. I ASKED HAD THE QUALITY OF THEIR VEHICLE PARTS GONE DOWN FROM WHEN THE ORIGINAL VEHICLE WAS MADE. SHE HAD NO RESPONSE, BUT PROVIDED YOUR WEBSITE AND TO FIND OUT IF THERE WERE ANY SIMILAR COMPLAINTS ON THE CATALYTIC CONVERTERS ON OTHER CHRYSLER OR DODGE VEHICLES. I TOLD THEM I WOULD NOT BE PURCHASING ANOTHER CHRYSLER OR DODGE PRODUCT. [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

TL* THE CONTACT OWNS A 2004 DODGE GRAND CARAVAN. THE CONTACT WAS DRIVING 15 MPH WHEN THE SMELL OF BURNED RUBBER EMITTED INSIDE OF THE VEHICLE AND FLAMES WERE VISIBLE FROM UNDER THE HOOD. IN ADDITION, THE HEAD LIGHTS FAILED TO ILLUMINATE INTERMITTENTLY. THE VEHICLE WAS DESTROYED AND THE FIRE WAS EXTINGUISHED. THE VEHICLE WAS TAKEN TO THE DEALER BUT NOT REPAIRED. THE CAUSE OF THE FAILURE WAS UNKNOWN. THE MANUFACTURER WAS NOT CONTACTED. THE VEHICLE WAS NOT REPAIRED AND THE VIN WAS UNAVAILABLE. THE FAILURE AND THE CURRENT MILEAGES WERE 121,000.

TL* THE CONTACT OWNS A 2004 DODGE GRAND CARAVAN. THE CONTACT STATED THAT THE VEHICLE WOULD INTERMITTENTLY STALL WITHOUT WARNING. THE VEHICLE WOULD IMMEDIATELY RESTART AND THE CONTACT STATED THAT THE FAILURE ONLY SEEMED TO OCCUR WHEN THE FUEL TANK WAS FULL. THE CONTACT PLANNED TO HAVE THE VEHICLE INSPECTED OR REPAIRED, IF NEEDED. THE FAILURE MILEAGE WAS UNKNOWN AND THE CURRENT MILEAGE WAS 72,000.

1. METAL COOLANT LINES GOING TO REAR HEATER FAILED ,MASSIVE CORROSION WHERE THE HEATER HOSE ATTACHES TO THE PIPE COMPLETELY ROTTED/RUSTED OUT, THE VEHICLE HAD 75K MILES ON IT. 2. IF THE COOLANT LEVEL GETS TOO LOW OF COURSE MY ENGINE WILL OVERHEAT AND SEIZE. 3. THE STEEL PIPES NEED TO BE REPLACED FOR ALUMINUM PIPES OR CORROSION PROTECTION FROM THE FACTORY THAT'S NEEDED TO WITHSTAND HARSH CLIMES, ESPECIALLY ONES WHERE SALT IS USED TO DEICE ROADWAYS. *TR

WE HAVE HAD OUR VAN IN FOR SERVICE AND OIL CHANGES IN THE PAST. THE ENGINE HAD LESS THAN 40,000 MILES AND WAS USING ALMOST 4 QUARTS OF OIL IN LESS THAN THREE MONTHS. THE LAST TIME IT WAS SERVICED, THE DEALER COULD NOT FIND ANY REASON WHY IT WAS USING OIL. THEY SAID TO KEEP AN EYE ON IT BY CHECKING IT FREQUENTLY, AND THEY COULD TRY TO MONITOR IT TO SEE WHY WE WERE LOOSING OIL. WE COULD ALWAYS FIND SMALL SPOTS OF OIL IN OUR DRIVEWAY AND ON PARKING AREAS/GARAGE FLOOR. THE DEALER DID CHECK THE VEHICLE AND SAID THEY COULD NOT FIND ANY OIL LEAKS. THEY DID HOWEVER FIND A LEAK IN THE TRANSMISSION LINE, WHICH DID NOT EXPLAIN WHY WE WERE HAVING TO REPLACE OIL ON A REGULAR BASIS. WE HAD JUST PLACED 4 QUARTS OF OIL IN THE VAN TWO DAYS PRIOR TO THE SERVICE APPOINTMENT. THE VAN WAS TOTALED IN AN AUTOMOBILE ACCIDENT THE NEXT MONTH, SO WE WERE NOT ABLE TO FOLLOW UP ON THE OIL LEAK PROBLEM BUT FELT THAT WE SHOULD REPORT THIS PROBLEM SINCE OTHER DODGE CARAVAN OWNERS HAVE HAD THE SAME PROBLEM WHERE THEY HAVE LOW MILEAGE ON THEIR VEHICLE, AND OIL LOSS FOR NO KNOWN REASON. *TR

I HAD CONTINUALLY ADDED OIL EVERY MONTH STARTING AFTER ABOUT 10,000 MILES. I CHANGED OIL EVERY 3-5,000 MILES. DRIVING BACK FROM UP NORTH AND I HEARD A TICKING NOISE. I HAD CHECKED THE OIL LEVEL BEFORE OUR TRIP ON 8-3-07 AND ADDED 2 QUARTS OF OIL TO BRING IT UP TO FULL. AS WE HAD THE WINDOWS CLOSED AS THE TEMP HAD FALLEN TO CHILLY, I COULD NO LONGER HEAR THE NOISE UNTIL WE WERE WITHIN MILE OF OUR HOME. IT BECAME LOUDER AND AS WE PULLED INTO THE DRIVEWAY, IT WAS VERY LOUD. I WAS GOING TO BRING IT TO A DEALERSHIP TO GET IT CHECKED OUT THE NEXT DAY, BUT THE VAN WOULD NOT START. I HAD IT TOWED TO THE CLOSEST DEALER AND THEY LOOKED AT IT THE NEXT DAY AND TOLD ME THAT THE ENGINE HAD BLOWN. THEY TOLD ME TO CONTACT CHRYSLER AS THEY WOULD TOO. I DID AND THEY TOLD ME IT WAS NOT GOING TO BE COVERED DUE TO LACK OF MAINTENANCE. THEY WANTED OIL CHANGE RECORDS AND I DID SOME MYSELF BUT HAD 3 FROM A LOCAL REPAIR SHOP. THEY WANTED 2 MORE AND I COULD NOT SUPPLY THESE AS I HAD DONE THEM MYSELF. I DID HAVE A RECEIPT FOR THE OIL I ADDED IN LAST JULY, BUT THAT WAS IT. I HAVE ABOUT 37,000-38,000 MILES ON THE VAN. THE DEALERSHIP WANTS ME TO PAY FOR THE TEAR DOWN OF THE ENGINE EVEN THOUGH I WAS TOLD THE FIRST WEEK THAT CHRYSLER HAD OK'D THE TEAR DOWN TO FIND THE PROBLEM. NOW THE DEALERSHIP CALLED ME AND WANTS ME TO PAY FOR A TEAR DOWN SO THEY CAN LOOK INTO WHY IT BROKE. I TOLD THEM , YOU ALREADY TOLD ME THAT YOU HAD THE OK TO DO THIS AND IT SHOULD BE ALREADY DONE. I WENT TO THE DEALERSHIP AND THE VAN WAS ON THE HOIST AND WAS PARTICULARLY DISASSEMBLED. THE DEALERSHIP WANTS ME TO PAY FOR THE TEAR DOWN AND A NEW ENGINE THAT WILL COST ALMOST $5,000. I HAVE IT DOCUMENTED ON AT LEAST ONE OIL CHANGE THAT IT HAD USED 2 QUARTS OF OIL BETWEEN CHANGES. I HAD NO LEAKS BELOW MY VAN SO I WAS UNAWARE THAT THIS ENGINE WAS EATING OIL. OTHER THAN HAVING TO ADD SOME EVERY MONTH. MORE IF YOU NEED IT. *JB

2004 DODGE GRAND CARAVAN CUSTOMER HAS CONCERNS WITH THE TIMING BELT**NAR**CC THE CRANK WAS UNDERSIZED ON THE BEARINGS AND THE BEARINGS WERE UNDERSIZED CREATING A LARGE GAP BETWEEN THE BEARINGS AND THE CRANK WHICH WAS CAUSING THE NOISE KNOCKING NOISE IN THE ENGINE. A FOREIGN PIECE OF METAL WAS FOUND UNDER THE MAIN BEARING CAP WHICH CAUSED EXTRA CLEARANCE. AND THE CRACK WAS ONLY TOUCHING TWO-THIRDS OF THE BEARING SURFACE. *JB

DT: CONSUMER'S WIFE WAS DRIVING NEAR HOME AND LOST POWER STEERING AND POWER BRAKES. SHE WAS ABLE TO STOP THE VEHICLE BY STANDING ON THE BRAKES. THE DEALERSHIP WAS CALLED AND THEY PICK UP THE VEHICLE. THEY REPLACED THE SERPENTINE BELT AND PULLEY. A YEAR LATER WHILE DRIVING ON THE INTERSTATE THE SERPENTINE BELT FELL OFF AGAIN IN THE MIDDLE OF HEAVY TRAFFIC. THE CONSUMER HAD TO PULL TO THE SIDE OF ROAD. THE DEALER WAS CALLED AND THEY DETERMINED THAT THE SERPENTINE BELT AND PULLEY HAD BROKEN AGAIN. IT WAS REPAIRED. CALLED THE MANUFACTURER TO REPORT THE PROBLEM. THE MANUFACTURER SAID THAT THERE WAS NOTHING THEY COULD DO ABOUT IT. NO MORE PROBLEMS AS OF YET. *AK *NM

VAN FELT LIKE IT WAS GOING TO STALL WHEN AT A STOP LIGHT OR STOP SIGN OR IF IDLING. ALSO BATTERY DIED TWICE WITHIN FIRST YEAR. HIGH PITCHED SQUEALING DEVELOPED ABOUT 6 MONTHS AFTER PURCHASE. THE VAN VIBRATES, ESPECIALLY STEERING WHEEL ONCE SPEED EXCEEDS 50 MPH. THE DEALERSHIP REPLACED THE BATTERY AND ALSO THE ALTERNATER DUE TO A DEFECTIVE MECHANISM. THE SQUEALING HAS STOPPED. ADJUSTMENTS WERE ALSO MADE TO REDUCE THE ROUGH RIDE OF THE VEHICLE. THE VIBRATING STILL OCCURS AND IT IS NOT SMOOTH WHEN ON THE HIGHWAY GOING AT SPEEDS IN EXCESS OF 50 MPH. *AK

WHEN IN DRIVE AND SITTING AT STOP LIGHT OR STILL THE MOTOR RUNS ROUGH. IT FEELS LIKE THE ENGINE WILL SHUT OFF.*AK