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full bulletin at NHTSA ↗2006 Chrysler 300 fuel system problems
moderate 218 complaints filed with NHTSA · avg repair $1,200 · see fuel system across all vehicles →
Failure mileage
Complaints
218
Recalls
0
Avg fix
$1,200
1crash
When does it fail?
Of the 218 fuel system complaints filed for the 2006 Chrysler 300, 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 4 model years of Chrysler 300 we track for fuel system problems, this one carries the most owner complaints on file — 218.
Owners have filed 218 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.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering fuel system on this vehicle — documented repair instructions, service campaigns, or warranty extensions sent to dealers. A TSB isn't a recall (it's not a free safety remedy), but it's the manufacturer acknowledging the issue and how to fix it.
Engine Stall Immediately Following Fuel Tank Fill-Up (X53 Lifetime Warranty Extension) This bulletin involves replacing the fuel tank with a revised part. Some customers may experience an engine stall condition just after filling the fuel tank. The integral mulit-functional control valve may allow liquid fuel to enter the evaporative emissions system causing a rich fuel condition when the purge system is initiated..
full bulletin at NHTSA ↗Engine Stall Immediately Following Fuel Tank Fill-Up (X53 Lifetime Warranty Extension) This bulletin involves replacing the fuel tank with a revised part. Some customers may experience an engine stall condition just after filling the fuel tank. The integral mulit-functional control valve may allow liquid fuel to enter the evaporative emissions system causing a rich fuel condition when the purge system is initiated..
full bulletin at NHTSA ↗Engine Stall Immediately Following Fuel Tank Fill-Up (X53 Lifetime Warranty Extension) This bulletin involves replacing the fuel tank with a revised part. Some customers may experience an engine stall condition just after filling the fuel tank. The integral mulit-functional control valve may allow liquid fuel to enter the evaporative emissions system causing a rich fuel condition when the purge system is initiated..
full bulletin at NHTSA ↗LOOSE FUEL CAP MESSAGE OR MALFUNCTION INDICATOR LAMP ILLUMINATION FOR DIAGNOSTIC TROUBLE CODE P0457 - EVAP SYSTEM - LOOSE FUEL CAP.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
Owners of 2006 Chrysler 300s with Hemi engines describe a recurring fuel-system defect: the engine stalls without warning within a few minutes or 1–2 miles after filling the fuel tank to capacity. The stall strips all electrical power, killing the engine, power steering, and power brakes—a terrifying situation in traffic that nearly caused multiple collisions. Restart usually works after several attempts or a brief pause, but the problem reoccurs on the next full fill.
Owners traced the root cause to a faulty check valve (also called a float valve or rollover valve) integral to the fuel tank. When the tank is full, this valve allegedly leaks or sticks open, allowing raw fuel to overflow into the charcoal vapor canister and purge system, flooding the engine. Most dealers confirmed fuel tank replacement—at costs between $1,200 and $1,905 for parts and labor—as the only permanent fix. Many owners report being steered toward a workaround: never fill the tank past 3/4 full, which eliminates the problem but defeats normal vehicle use.
NHTSA investigation PE13016 (closed February 2014) documented the defect and prompted Chrysler to extend fuel-tank warranty coverage, but only for select VINs and only for owners notified before the January 2014 deadline. Most complainants report their VINs were excluded, their warranty claims denied, and no notification letter ever received from Chrysler—leaving them to cover repair costs themselves despite owning identical vehicles with identical symptoms.
Same Chrysler 300 fuel system reports on nearby years: 2005 · 2007
Failure modes owners describe
Engine stalling after refueling with full tank
Engine dies or stalls within minutes to several miles after filling the fuel tank to full capacity. Loss of all electrical power, steering, and braking assistance occurs. Vehicle typically restarts after several attempts or a brief wait, but stalling recurs on subsequent refueling cycles if tank is filled completely.
When: Occurs after filling fuel tank to full; symptoms typically emerge 0-2 miles from gas station or within 1-5 minutes after refueling. Some owners report 6-8 miles of continued stalling if tank was topped off.
Symptoms owners cite: Engine dies while driving or idling after refueling; Loss of power steering and power brakes; Loss of all electrical power briefly; Vehicle requires multiple restart attempts; Engine sputters, surges, or jerks before stalling; No check engine light or diagnostic codes present in most cases; Symptoms subside as fuel level drops below full
Repairs/costs cited: Fuel tank replacement cited as primary repair in multiple narratives, costs ranging $1,200–$1,905 for parts and labor. Some owners replaced vapor canister ($516), purge solenoid, purge valve, evap canister, and fuel pump components before ultimately requiring tank replacement. One owner: vapor canister replacement $379.45, then PCM replacement $1,018.61, then sensor replacements and eventual tank replacement. Workaround reported by dealers and owners: do not fill tank to capacity; fill only to 3/4 full eliminates the problem.
Recalls/TSBs owners mention: NHTSA investigation PE13016 (opened January 2013, closed February 2014) concluded with Chrysler extending lifetime warranty on fuel tanks for affected vehicles. However, warranty applied only to select VINs notified prior to the January 2014 deadline; many owners report their VINs were excluded despite having identical vehicles and symptoms. Chrysler cited two different fuel tank sales codes (NSK vs NSKS) and different manufacturing plants; only certain production batches were covered. No formal recall issued. Owners cite Chrysler's refusal to honor extended warranty claims and lack of notification letters to affected owners.
Engine stalling during turns or rapid acceleration after refueling
Engine stalls specifically when driver makes sharp turns (left or right), accelerates from a stop, or applies braking force shortly after filling tank. Loss of power steering and braking occurs; vehicle requires restart. Pattern occurs when tank is full or nearly full.
When: Occurs after refueling; stalling triggered by turns, hard stops, or quick acceleration when fuel tank is full or near full. One owner describes being able to replicate stalling on demand after learning trigger.
Symptoms owners cite: Engine stalls during sharp left or right turns; Engine stalls during hard acceleration from stop; Engine stalls during hard braking situations; Loss of power steering and power brakes; No warning or diagnostic codes; occurs without engine light; Stalling does not occur if driver maintains steady speed or avoids maneuvers
Repairs/costs cited: Fuel tank replacement typically prescribed. One owner quoted $1,800 for tank replacement and lines. Workaround: avoid sharp turns and rapid acceleration after refueling; drive cautiously and keep speeds above 40 mph immediately after filling.
Recalls/TSBs owners mention: No specific manufacturer response cited for this variant in narratives.
Fuel overflow into charcoal canister and purge system contamination
When fuel tank is filled to capacity, fuel overflows or leaks from the fuel tank into the charcoal (vapor) canister and purge valve due to a stuck or failed check valve (rollover/float control valve) in the fuel tank. Contaminated canister then floods the engine with raw fuel, causing the stalling and starting difficulty.
When: Begins immediately after or within minutes of refueling with a full tank. Issue persists as long as tank remains full or near full.
Symptoms owners cite: Contaminated fuel in vapor canister detected during diagnosis; Raw fuel flooding into engine after fuel fill; Engine stalls with strong fuel smell; Difficulty restarting after stall; Canister and purge solenoid visibly saturated with fuel
Repairs/costs cited: Requires replacement of fuel tank (because valve is integral to tank and cannot be serviced separately), charcoal canister, and purge solenoid. One dealer's diagnostic work: 'REMOVED EVAP CANISTER TO CHECK FOR FUEL LIQUID [found saturated]; REPLACED GAS TANK AND TRANSFERRED NEEDED PARTS. FLOW CONTROL VALVE NOT SEALING, REPLACED CANISTER, SATURATED WITH FUEL. REPLACED PURGE SOLENOID, ALSO SATURATED.' Multiple owners cite $1,200–$1,500 for fuel tank; additional $500+ for canister and solenoid.
Recalls/TSBs owners mention: No explicit warranty coverage unless VIN included in PE13016 extended warranty program (most owners claim exclusion).
Slow or difficult fuel tank fill rate (backflow/splash-back)
Fuel pump nozzle repeatedly clicks off or shuts down prematurely when attempting to fill the tank due to fuel backflow or 'splash-back' in the filler tube. Owner must reposition pump nozzle multiple times or fill takes 20–30 minutes to complete. May be related to vent valve malfunction.
When: Occurs during refueling; develops concurrently with stalling problem in some cases.
Symptoms owners cite: Fuel pump nozzle shuts off repeatedly during fill; Fuel backflow or splash-back in filler tube; Filling takes 20–30 minutes instead of normal 5–10 minutes; Requires repositioning pump nozzle to complete fill
Repairs/costs cited: No direct repair cited in narratives. Presumed to be remedied by fuel tank replacement, as vent valve is integral to tank.
Repeat stalling and rough running after component repairs
After dealer replaces vapor canister, purge solenoid, purge valve, PCM, or other emissions components, the vehicle continues to stall after refueling. Multiple repair attempts by dealership fail to resolve the underlying issue because the root cause is the faulty fuel tank valve, not the downstream components.
When: Occurs repeatedly across multiple service visits over weeks or months as dealers attempt diagnosis and replacement of non-tank components.
Symptoms owners cite: Engine stalls after each fuel fill despite recent repairs; Dealer replaces multiple parts (canister, solenoid, valve, PCM, sensors) without success; Dealership runs diagnostic computer for extended periods but finds no codes or issues; Vehicle condition worsens or remains unchanged after repair
Repairs/costs cited: One owner example: paid $379.45 for proportional valve/purge valve replacement and system updates (12/16/2013), then $1,018.61 for PCM replacement after continued stalling, then told sensor replacement needed. Another: dealership charged $760 for cam-crank sensor replacement, then $630.89 for evap canister and purge solenoid, then finally identified fuel tank issue ($1,800 quoted). Total diagnostic and repeat repair costs often exceed $2,000–$3,000 before correct diagnosis.
Recalls/TSBs owners mention: Dealerships acknowledged the fuel tank defect in some cases after multiple failed repair attempts, but offered no goodwill support; customers charged full tank replacement cost even after paying for unrelated repairs.
Synthesized from 218 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 5 most recent
After fueling the Chrysler 300c the car will crank just fine and run for a minute or so but then stalls out. This scenario continues for about 5 to 8 times before it is safe to get back on the road. It has also died while driving shortly after fueling causing the power steering to stop making it extremely difficult to steer the car off the road to safety. This is very upsetting and unsafe for my…
Vehicle stalled after refueling. Filling the gas tank to full without 'topping off' will cause the car's engine to stall without any prior warning. No dtcs/miles are set. Can be restarted with some difficulty. The stall will occur at any engine/vehicle speed and will happen within the first 5 minutes of driving the car after refueling. The problem can be avoided by not filling the tank past…
When the Chrysler 300 hemi 2006 receives a full tank of gas, the Chrysler 300 hemi 2006 shuts off after the initial start of the engine and an additional two to three times. After several starts of the engine, the Chrysler 300 hemi 2006 begins to move, but stalls and chokes while in motion. During the stalling and choking the Chrysler 300 hemi 2006 looses steering ability. *tr
After refueling, car stalls. This happens after driving approximately 2 to 3 minutes after leaving gas station. The stall has taken place at intersections, while at a complete stop and while driving no more than 5 -10mph after leaving the gas station.. Car restarts after several attempts in neutral. When each incident occurs, the oil icon comes on, however the oil level is not low. On one…
The contact owns a 2006 Chrysler 300C. The contact stated that the fuel tank was previously replaced under an unknown extended warranty coverage; however, after the repair, the vehicle experienced a failure. The contact stated that after refueling the vehicle and driving at slow speeds, the vehicle stalled. The contact stated that the failure recurred several times while driving and coming to a…
Had fuel system trouble with your 2006 Chrysler 300?
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 2006 Chrysler 300?
It's a documented issue but not catastrophic. 218 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 201 complaints that reported odometer mileage, most fuel system failures cluster between 44,266 and 91,000 miles, with the median around 67,000. A quarter of owners report trouble before 44,266; a quarter make it past 91,000. 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/2006/Chrysler/300.
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.