Rick hendrick Jeep/Chrysler, north charleston, sc did not perform the necessary job duties to remedy the safety recall of the fuel pump on my 2005 Chrysler pacifica. The dealer had my vehicle for 4 days, but the recall was not properly corrected which caused major danger to myself and my family! I first began to smell gas on tuesday evening after I filled my gas tank and continued to smell…
2005 Chrysler Pacifica fuel system problems
moderate 70 complaints filed with NHTSA · avg repair $1,200 · see fuel system across all vehicles →
Failure mileage
Complaints
70
Recalls
0
Avg fix
$1,200
1crash
1injury
When does it fail?
Of the 70 fuel system complaints filed for the 2005 Chrysler Pacifica, here's the actual mileage breakdown — failures cluster heaviest at 50,000-75,000 mi.
0-25k
25-50k
50-75k
75-100k
100-125k
125-150k
150k+
Each bar shows the share of total complaints filed at that mileage range. Peak failure window highlighted. Some owners report problems earlier; some make it well past 150,000 miles symptom-free. Maintenance habits and driving conditions shift the curve as much as mileage alone.
What stands out
Of the 5 model years of Chrysler Pacifica we track for fuel system problems, this one carries the most owner complaints on file — 70.
Owners have filed 70 fuel system complaints with NHTSA against this vehicle, but no formal recall covers the issue — the federal record reflects what manufacturers have admitted, not everything owners are reporting.
The failure pattern owners describe
Buyer takeaway: The 2005 Pacifica has a systemic fuel system problem affecting many owners: erratic fuel gauges that drop to empty while fuel remains in the tank, engines stalling during turns or stops, and tanks that won't accept full capacity. Dealers struggle to fix these issues permanently, recalls haven't resolved the problems for most owners, and some cars have required multiple fuel pump replacements without success.
The 2005 Pacifica fuel system generates three core complaints across this 70-complaint cluster. First, the fuel gauge is unreliable: it drops suddenly from half or three-quarters full to empty, then climbs back without refueling, while the tank often accepts only 5–15 gallons despite a 23-gallon capacity. Second, the engine stalls without warning when fuel reads half-tank or below—especially during left turns, hills, or traffic stops—causing loss of power steering and braking. Third, the fuel tank's fill valve malfunctions: the pump nozzle clicks off repeatedly and gas spills rather than entering the tank.
Dealers consistently struggle to duplicate these problems on first visits, leaving owners stranded for weeks awaiting fuel pump backorders. When repairs are attempted—level sensors, fuel pumps (primary and secondary), PCM reprogramming, tank hoses, and sending units—they often fail to resolve the issue permanently. Recall 06V432000 (PCM reprogramming and fuel pump module replacement for certain 2004–early 2005 models) has not fixed the stalling or gauge problems for most owners who report it. Many owners are told their VIN falls outside recall scope. A few owners report dealers installing defective replacement fuel pumps during recall work. Additionally, the throttle body sticks on acceleration at low speeds and recurs after repair. Cold starts hesitate, and the unshielded plastic fuel tank punctures easily.
Same Chrysler Pacifica fuel system reports on nearby years: 2006 · 2007
Failure modes owners describe
Fuel Gauge Malfunction and Erratic Readings
The fuel gauge drops suddenly from half or three-quarters full to empty, then climbs back up without fuel being added. Owners report the gauge reading empty while 5–16 gallons remain in the tank. Filling often takes only 5–15 gallons despite a 23-gallon tank capacity. The gauge fails to track actual fuel levels reliably.
When: Typically observed around 45,000–75,000 miles; some occur early after purchase or within weeks of ownership.
Symptoms owners cite: Fuel gauge drops instantly from 1/2 to 3/4 tank to empty; Gauge reads empty while fuel remains in tank; Fuel gauge climbs back to half or full without refueling; Inaccurate miles-to-empty display; Only 5–15 gallons accepted by pump despite 23-gallon tank
Codes mentioned: P1861 (fuel tank siphon line disconnected, per owner report)
Repairs/costs cited: Dealers replaced level sensors, fuel pump modules, fuel pumps (primary and secondary), tank hoses, and tank sending units on multiple visits without permanent resolution. One owner cited repeated replacements from 60k to 84k miles; another had level sensors, pump modules, and hoses replaced on six+ dealer visits.
Recalls/TSBs owners mention: Recall 06V432000 (PCM reprogramming and fuel pump module replacement for 2004–early 2005 build dates) did not resolve the issue for many owners. Owners report dealers claiming no recall applied to their VIN.
Engine Stalling—Low Fuel Conditions and Turns
Engine stalls without warning when fuel gauge shows half-tank or below, especially during left turns, hills, or at traffic stops. Stalling causes loss of power steering and braking. Vehicle typically restarts after being placed in park; however, on downhill inclines restart fails.
When: Occurs throughout ownership; noted from under 13k miles to 80k+ miles. Often happens after recall work performed.
Symptoms owners cite: Engine stalls at stop lights and traffic stops; Stalling during left turns at highway and low speeds; Stalling when descending hills or on downhill inclines; Stalling occurs when fuel gauge near or below half-tank; Loss of power steering and braking during stall; Vehicle restarts easily in park but may not restart on hills; Stalling after recall F44 fuel pump work performed
Codes mentioned: No codes found on multiple dealer visits, P1861 (fuel tank siphon line disconnected, per one owner)
Repairs/costs cited: Dealers unable to reproduce problem on first 2–3 visits. One owner had car at dealer for 28 days waiting for fuel pump backorder. Dealers replaced fuel pumps (primary and secondary), PCM modules, and level sensors. One repair involved both fuel pump modules; another required fuel pump replacement after recall. Despite these repairs, stalling persisted for many owners.
Recalls/TSBs owners mention: Recall 06V432000 issued for fuel pump module and PCM reprogramming (certain 2004–early 2005 build dates). Many owners report recall did not resolve stalling. Some owners told their VIN was outside the recall scope. Chrysler told one owner (per dealer) that stalling when fuel drops below half-tank was 'normal behavior.'
Fuel Tank Overfill Protection Failure
The fuel tank's automatic shutoff (rollover ball or vent system) malfunctions, preventing the tank from accepting its full 23-gallon capacity. Nozzle clicks off repeatedly during fueling, and gas spills or backs up. Tank only accepts 4.5–15 gallons at fill, leaving the remaining portion inaccessible.
When: Occurs throughout ownership; one case at 120,000 miles.
Symptoms owners cite: Fuel pump nozzle clicks off repeatedly during fill-up; Only 4.5–15 gallons accepted by tank despite 23-gallon capacity; Fuel spills from filler neck when attempting to add fuel; Cannot force more fuel into tank without spillage; Tank hose line on one end is part-full, other end at filler neck part-full
Repairs/costs cited: One owner reported dealer identified a stuck 'valve' inside the tank and ordered the part but status unknown. Another had fuel hoses repaired on 4/20/2007. Mechanics found no leaks despite customer belief fuel was being siphoned.
Recalls/TSBs owners mention: No recall issued specifically for overfill protection. Dealers attempted repairs via hose or valve service without documented success.
Throttle Body Sticking / Accelerator Pedal Resistance
Gas pedal requires excessive force to depress, causing the vehicle to lurch forward suddenly once the pedal finally moves. Problem is intermittent and recurs after repair.
When: Observed at low speeds (2–5 mph) during parking and at highway speeds. Problem recurs 18 months after initial dealer repair; another owner at 42,000 miles.
Symptoms owners cite: Gas pedal sticks and requires forceful depression; Vehicle lurches forward suddenly when throttle engages; Pedal sticks during acceleration and at stops; Unwanted rapid acceleration when pedal breaks loose; Problem occurs almost every time car is started at low speeds
Repairs/costs cited: Dealers performed throttle body assembly replacement (~$190–$200 labor). One owner paid ~$190 out of pocket at 42k miles because warranty did not cover wear-and-tear. Recurrence documented 18 months after original repair; dealer reluctant to help on repeat issue.
Recalls/TSBs owners mention: No recall issued. Dealers acknowledge this is a known issue with prior knowledge and standard repair, but some refuse to service repeat occurrences under warranty.
Post-Recall Fuel Pump Defect
Fuel pump installed as part of recall 06V432000 (December 2006) was defective and required replacement within days. Subsequent replacement pump also failed at highway speed with no warning.
When: Replacement fuel pump failed 1 day after recall service (12/19/2006); second replacement failed at highway speed 3 days after second replacement (12/22/2006).
Symptoms owners cite: Vehicle would not start 1 day after recall fuel pump replacement; Vehicle lost all power at 80 mph on 12/22/2006 with no warning lights; No indication of problem before sudden loss of power
Repairs/costs cited: Dealer replaced defective fuel pump on 12/18/2006 with another pump; that pump also failed. Owner able to coast to roadside and restart vehicle after loss of power.
Recalls/TSBs owners mention: Recall 06V432000 involved fuel pump module replacement; owner received defective replacement parts.
Cold Start Hesitation and Long Crank
Vehicle hesitates or takes excessive time to start when engine is cold (after overnight sitting). Long crank persists even after dealer service.
When: Noticed in first week of June 2006; observed on overnight cold starts beginning November 2005; one owner reported long crank in late August that never resolved.
Symptoms owners cite: Vehicle does not start on first attempt after overnight sitting; Engine hesitates when taking off from a stop after overnight; Long crank condition persists; Difficult cold starts beginning in November (winter weather)
Repairs/costs cited: Dealer attributed long crank to loose gas cap allowing air into tank, but owner disagreed. Long crank was never resolved despite diagnostics.
Recalls/TSBs owners mention: Dealer misdiagnosed cause. No recall or service bulletin for cold start hesitation documented in narratives.
Secondary Fuel Pump Failure
Secondary (jet) pump fails, leaving the vehicle with only the primary fuel pump and a limited, inaccurate fuel supply. Vehicle has two independent fuel tanks and two pumps by design.
When: Diagnosed after vehicle stalled repeatedly at traffic lights; determined later during service.
Symptoms owners cite: Vehicle stalls at traffic lights without warning; Stalling cannot be duplicated by dealer on initial visits
Repairs/costs cited: Dealer determined secondary pump had failed. Repair not detailed in narrative.
Recalls/TSBs owners mention: No specific recall for dual-pump system mentioned.
Fuel Line Leak
Fuel leaks from the fuel line connection where hoses are clamped under the fuel tank. Recall work on fuel pump seal was not completed properly at dealership, leaving the vehicle unsafe.
When: Reported after recall work; one incident at 120,000 miles.
Symptoms owners cite: Excessive gasoline smell after filling tank; Fuel leaking from under tank at hose clamp area; Fuel puddle on ground during gas station fill-up
Repairs/costs cited: One owner reported recall work at Rick Hendrick dealership failed to apply correct seal, causing leak. Dealer finally found fault and repaired. Another case at 120k miles: leak under tank where fuel lines were clamped; vehicle not repaired per narrative.
Recalls/TSBs owners mention: Recall 06V432000 mentioned fuel pump module replacement. In one case, dealership failed to complete recall work properly.
Fuel Tank Vulnerability to Road Debris
Unshielded plastic fuel tank in the forward area is easily punctured by road debris.
When: Reported after impact with metal debris while driving on highway.
Symptoms owners cite: Fuel leaks after impact with road debris
Repairs/costs cited: Fuel tank was temporarily patched to stop leak. High-density polyethylene plastic construction noted as vulnerable.
Synthesized from 70 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 3 most recent
Car stall when making sharp left hands turns. It has done this two consecutive days in a row. I searched the VIN on Chrysler and there are no open recalls. The found that there was a recall for this on 2005 pacifica's but I am unable to find out if mine was ever corrected. *tr
Tl* - the contact called received recall notice 06v432000 . She stated that repair was done on 12/18/06 for the fuel pump. The contact states that on 12/19/06 the vehicle wouldn't start. The vehicle was towed by aaa to dealership, the dealership told her that the replacement fuel pump was defective, and they replaced it again. The contact stated that on 12/22/06 after 2nd replacement she…
Had fuel system trouble with your 2005 Chrysler Pacifica?
File a complaint with NHTSA → It's free, official, and how every report above got here — owner filings are the federal safety record this page is built on.
Common questions
How serious is the fuel system problem on the 2005 Chrysler Pacifica?
It's a documented issue but not catastrophic. 70 complaints have been filed. Repairs average $1,200 and most owners catch it before it causes a breakdown.
At what mileage does the fuel system typically fail?
Across the 56 complaints that reported odometer mileage, most fuel system failures cluster between 33,496 and 70,000 miles, with the median around 52,000. A quarter of owners report trouble before 33,496; a quarter make it past 70,000. Maintenance history matters more than the odometer alone — this is the reported failure window, not a guarantee.
What does it cost to fix?
Independent shops typically charge around $1,200 for fuel system repairs on this vehicle. Dealer pricing tends to run 20-40% higher. The exact figure depends on the specific failure mode, parts availability, and your local labor rates. If you're outside factory warranty, an extended service contract often covers this category.
Are there any recalls related to fuel system?
No active recalls currently cover fuel system issues on this vehicle. The complaints filed represent owner-reported failures that haven't risen to the level of a manufacturer-issued recall — but they're still worth knowing about before you buy or budget for repairs.
Related
Complaint and recall data sourced from the National Highway Traffic Safety Administration (NHTSA)
public records database. Verify the raw federal record at
nhtsa.gov/vehicle/2005/Chrysler/Pacifica.
Severity ratings are derived from reported crashes, fires, injuries, and fatalities. Repair cost estimates are
independent-shop national averages and may differ in your area. Some links on this page are affiliate links.