New to the forum. I searched for this topic but found nothing. I thought I would share my experience with all of you. I discovered a fuel leak coming from top of the fuel tank of my 2004 Grand Caravan SXT. When I lowered tank, I found that fuel pump has hair line cracks on the housing (see red markings in pics--those are cracks not dirt), and fuel was seeping out of those cracks. It seems like a very unusual defect. I know of nothing that would have contributed to that development (i.e., factory fuel pump and tank had never been disturbed and vehicle has always lived in Southern California). I've googled recalls or tsbs for this issue but found nothing.

 

I'm not a tech but based on the location of the cracks it appears the connecting fuel line was torquing the tube pictured upwards. Any indication of the connecting line being misrouted or misaligned?

This could be a safety issue effecting many vans. I would head to the NHTSA website and file a complaint. When they get enough complaints on the same subject the NHTSA will investigate and possibly force a recall or at least a TSB.

Just curious. Was the van hard to start?

 

I had that same thought of the pump being torqued up because of the location of those cracks, but I concluded that wasn't the case because the fuel line is made out of plastic (or vinyl or something) and did not seem misrouted (no tension on it). Additionally, I'm the original owner of the vehicle and the tank had never been removed or tampered with. I'm not an automotive tech either, but I concluded that they must be weak points in the design of that fuel pump housing. That's why I looked for recalls or TSBs on this issue; maybe it's happening to all Caravans with this same pump. Finding nothing, I thought I would sound the alarm here at this forum for people to be on the lookout for this problem.

But maybe it's an aberration, and it only happened to my vehicle...

By the way, the van had no starting issues. Despite the seepage, it seem to run fine.

 

u could of just got a bad pump with manufactoring defect or who installed at factory may of put force on it to have it over yrs slowly degrade. i just put in new one and be done with it cause chryler or dealer wount probably do anything. You could try to send pictures and milage to chrysler and see but i doupt it.

 

I doubt it too. (lol)

 

same 2004 sxt grand caravan. the tank it leakinging the same place. I am figuring it is due to a heat issue with he cracked pump. I am an engineer and mechanic on my own car. I am registering for a recall also. Of coarse dodge will not own up to it just like they don't honor there 100,000 mile warranty.

 

I to have been having the same issue with my fuel pump. It is cracked in the exact same places shown above. Found on Amazon for $139.

 

I have the same 2004 sxt grand caravan with the same leak.

 

I roughed it up with sand paper and jb welded marine version around it=no more problems for about 12 months now !!!!

 

Having the same issue on my 2005 caravan. Looked like fuel was seeping from no where. Going to replace the part asap. Thanks for the detailed pics and post.