Several times in past year after filling the gas tank, shortly after driving away from gas station the engine misfires and stalls. This has been a safety hazard when merging into traffic. This problem is widely noted in forums on the internet for Chrysler minivans, for many other model years including the 2005. The best explanation being given (link follows) is that the vapor/liquid separator valve on top of the fuel tank has failed, a part that is not replaceable--the entire fuel tank must be replaced. Some report it happened when their minivan was brand new. https://ricksfreeautorepairadvice.com/engine-stalls-after-filling-tank-chrysler-minivan/

- Tigard, OR, USA

On the evening of 03/04/2021 @ 9:00pm. Whilr driving home from the grocery store doing approx 35 mph, my van suddenly lost all power and ability to use power steering and use of brakes. I had my children in the vehicle at the time and they were able to help me get the van out of the travel lane and safely into a parking lot. Van did not want to start after cutting off the ignition switch and cutting it back on. When I restarted the van it wouldnt accelerate passed 15mph with the pedal all the way down to the floor then it constantly stalled out 8-10 times the last mile from home.

- Lenoir, NC, USA

Car will stall a few minutes after filling the gas tank. It will stall in the middle of driving on the road and will not restart for 20 minutes causing a dangerous situation.

- Spring Valley, NY, USA

2205 Dodge Grand Caravan stalls after refueling. Multiple occurences. Happens in motion straight line, while accelerating.

- Spartanburg, SC, USA

The contact owns a 2005 Dodge Grand Caravan. After refueling the vehicle, the engine started and stalled. The oil warning indicator illuminated on the instrument panel. The failure was intermittent. The vehicle was not diagnosed or repaired. The manufacturer was notified of the failure. The approximate failure mileage was 105,000.

- Clarksville, TN, USA

Every time I fill up the vehicle with gas, it stalls every time within the first few minutes, last week daughter was merging into traffic when it happened and almost got rear-ended. This has been happening for a while now. Last winter I wasn't able to fill the vehicle, the pump kept shutting down but that went away after the weather warmed up.

- Maple Shade, NJ, USA

Engine sputters or stalls shortly after filling the tank. It typically happens when taking off at one of the first intersections after filling the tank. It put me in danger, because it stalls in the middle of the road without warning. This has happened several time in 2015. The date below is approximate for the time the van was last filled up.

- Galt, CA, USA

The vehicle stall immediately after 1st startup fill up of the gas tank. The steering locks and car engine hesitates and dies. After waiting couple of minutes, the car will start up and not have the problem until next refill of the gas tank. I never overfill the gas tank. The problem is similar to an existing recall on 19 gallon gas tanks on Dodge chargers.

- Burke, VA, USA

After I fill up the gas tank the van stalls within a couple of minutes. This has happened numerous times and has almost caused several accidents.

- Weston, FL, USA

While slowing down motor will try and shut off. If you come to a stop it will shut off. Seat belts do not lock in place. Rear windshield wiper will not move. Passenger side cargo door will not unlock. Some settings for heat and ac will not work. Left turn signal won't shut off after turning.

- Lafayette, IN, USA

The engine stalls while driving within five or six minutes after filling the gas tank. This has happened multiple times.

- Greenwood, IN, USA

Car stalls when I fill the tank up with gas. The car stall out shortly afterwards while driving.

- Medford, NJ, USA

Vehicle stalled twice after filling up with gas. First stall happened approximately 500 feet from filling station, while still in a parking lot. The second stall happened approximately 0.5 miles from the filling station while turning from a roadway into a business. Each stall required several cranks of the engine to re-start. When the engine quits, the power steering also goes away. This has been an intermittent occurrence since early 2013, with it becoming a regular occurrence after each gasoline fill up (later in 2013). The tank is always filled until the pump shuts off. It is never partially filled, so I cannot say if it only occurs with a full fill up. This is the first time I decided to research the situation and file a complaint.

- Woodstock, GA, USA

2005 Dodge Caravan SXT stalls unexpectedly at highway speeds and at low speeds shortly after being fueled to a full tank of gas. This has been happening more often after the mileage has gone over 100000 mile. It has been starting back up after it stalled but has taken longer to start with each passing stall. If I disconnect the negative battery post wait a few moments and reconnect the van will get me home till the next day when the stalling start again. After the gas tank is below 3/4 the stalling issue goes away. In it's current condition not a very reliable or safe automobile for any family to be using on the highways.

- Rockford, MI, USA

Took ownership of the vehicle in January 2014. Nearly every time the gas tank has been filled up (to full), the vehicle will run ok for a brief period of time, it will then begin to buck and stall. This happens at nearly any engine speed. Once the vehicle stalls it is difficult to restart for one attempt. After the gas tank gets just under full the operation is completely normal. This is dangerous as usually you are in traffic.

- Cleveland, OH, USA

Have had numerous problems with van starting 3 months after purchase. Dash lights flash but only for seconds so no code can be read. Electric windows failing, batteries replaced numerous times. Have gotten to point I purchase window tracks and replace myself to save on cost. Most recently dash lights and headlights flashing rapidly radio and air go out and vehicle wanting to stall. This is a conversion van by braun. Had handicapped person in wheelchair in passenger side front. Van stalled in intersection but was able to get off to side of road. Where I was, I could not get wheelchair out of van. We could have been killed not to mention I live in Florida and heat was at a feel like temp of 108. After 10 or 15 minutes van restarted and was able to limp home. Auto electric repair shop replaced ignition wiring harness but after 30 days it is now doing same again only worse. I now have no Transport for handicapped person because why fix something that cannot be resolved without changing every part to figure out real problem. I know even if the BCM is replaced that is only temporary according to other reports of same problem I have.

- Deltona, FL, USA

The contact owns a 2005 Dodge Grand Caravan. The contact stated that after refueling and driving at 25 mph, the vehicle stalled without warning. The contact mentioned that the vehicle stalled after refueling. The vehicle was able to restart. The vehicle was taken to the dealer where the failure was not able to be duplicated. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was 75,000. Updated 10/8/14 10/24/14 updated 02/03/15

- Chino Hills, CA, USA

Nearly every time the we fill the tank full of fuel the engine shuts down after leaving the station. Typically it will happen mid turn while pulling out of the station or else within a block of leaving. When it happens the steering stops working normally. We have to shift the vehicle to neutral and restart it and then put it back in drive and go.

- Rowley, IA, USA

I originally called Dodge when this issue started and they would not do anything about it but when we would put the van in reverse the engine would not go into reverse and if you were not listening for it to "catch" you would put on the gas and be going forward. After calling a few times we just gave up and began a habit of shifting into reverse and making sure the vehicle was indeed in reverse. After several years of this we started having a problem with the vehicle speed. The engine would rev but the vehicle would not go if it was under any kind of strain, uphill or grade. After replacing everything from fuel injector to catalytic converter to spark plugs, wires and sensors and spending close to $1000 on it we ended up in a transmission repair shop which found our problem to be a cracked flex plate. That was $1500 more but the problem was fixed. The reverse is now working properly as well so I feel that this flex plate may have been the reverse issue as well.

- Natural Bridge, VA, USA

After filling vehicle with fuel, our van has been stalling upon stopping at a light within 5 minutes of leaving gas station. Most recently vehicle cut off less than 1/4 mile after refilling when driving on road. When this happens, electric of vehicle shuts off along with losing power steering. The problem of vehicle shutting off has gone on intermittently for about 1-2 years now but is getting worse. Until about a week ago, this always happened at a stop but the last incident is concerning considering it happened while the vehicle was in motion. This is a serious safety issue, especially considering my wife uses this as primary transportation for her and our 3 children. What if this cuts off on the highway or in an intersection? I did a lot of research online trying to find possible root causes. There seems to be an overwhelmingly large number of people having this issue with the 3.8 liter V6 on Dodge/Chrysler minivan models in the 2003-2007 range. I am also told the only way to fix this is to replace the entire gas tank due to a faulty valve/separator. I hope that Chrysler is willing to do something about this problem at no cost to the customer considering the high level of danger that we are presented with here.

- Burlington , KY, USA