2006 Dodge Charger fuel system problems

Engine stalls and dies shortly after filling the gas tank to full or topping off, typically within a few blocks or miles of the station. Loss of power steering and braking occurs. Restart is difficult and requires multiple attempts. The problem decreases or stops as fuel level drops below 3/4 tank.

When: Occurs immediately after refueling; mostly when tank is filled beyond 3/4 capacity. Some owners report issues starting around 2010–2012, others later. Severity worsens with humidity and cold weather.

Symptoms owners cite: Engine stalls without warning after refueling; Loss of power steering and brakes when stalling; Difficult or delayed restart requiring multiple attempts; Check engine light may or may not illuminate; Oil pressure warning light and chiming sounds reported; Car bucks, sputters, and hesitates before stalling; Stalling occurs at traffic lights, during turns, on hills, on-ramps, and highways; Problem resolves or diminishes once fuel level drops; Stalling can occur within feet of gas station or after several miles of driving

Codes mentioned: No codes or check engine light in many cases, Engine misfiring codes reported in some instances

Repairs/costs cited: Owners report dealers and independent mechanics cite a faulty fuel tank shut-off float valve (integral to fuel tank assembly) as the cause. Full fuel tank replacement required at cost of $1,700–$3,000 plus labor. One owner was told tank costs $600 alone. Dealership noted parts often on backorder, creating multi-month delays for repair. Purge solenoid valve replacement attempted by one owner but did not resolve the issue. Replacing the entire fuel tank assembly assembly resolved the problem for owners who completed the repair.

Recalls/TSBs owners mention: Dodge/Chrysler issued Technical Service Bulletin #14-002-14 (February 2014) and extended warranty on fuel tanks. NHTSA Investigation PE13-016 established extended warranty coverage. However, multiple owners report Chrysler denied extended warranty claims citing VIN not being in the system, salvage title, or vehicle build month not covered. One owner received extended warranty letter (May 2014) but could not schedule repair due to parts backorder. Dealer advised owners not to top off tank; one advised owner to fill only 3/4 tank. Chrysler acknowledged the problem in emails to dealers but refused to expedite repairs or initiate full recall despite widespread complaints.

Strong odor of raw or unburned gasoline inside and around the vehicle when the engine shuts off, particularly noticeable near the driver-side door. Odor is intermittent but occurs in 90% of instances under certain conditions.

When: Occurs primarily when engine comes to a stop after driving; worse in cold weather, after extended driving followed by abrupt stop, and with half to three-quarter tank of gas. Some instances after short drives or long idle periods.

Symptoms owners cite: Strong to moderate odor of raw gasoline; Odor most noticeable under driver's side door area; Odor occurs when car comes to a stop; Intermittent but occurs in roughly 90% of situations; Worse in cold weather; Worse after driving several hours followed by abrupt stop; Can occur with any fuel level, though more common mid-range

Repairs/costs cited: Owner and two other people inspected vehicle under hood and underneath on a lift but found no visible leaks, broken or cracked hoses. Dodge dealership inspection (02/08/2011) could not identify cause. Multiple owners report similar issue on Charger owner forums (www.chargerforums.com) with no identified cause or repair.

Recalls/TSBs owners mention: Dodge dealership unable to diagnose despite inspection. No manufacturer statement or recall issued for odor complaint.

Gasoline overflows and spills from the fuel tank filler neck when attempting to refuel, even when pump shutoff engages at appropriate full level. Owner must position pump handle upside down at 10–11 o'clock angle to fill tank, or pump stops immediately.

When: Occurs during every or nearly every refueling since vehicle purchase (2005). Fuel overflow happens even after pump shutoff engages.

Symptoms owners cite: Fuel pump shutoff engages prematurely or immediately unless handle is held at awkward angle; Gasoline overflows and spills at filler neck during refueling; Must manipulate pump handle upside-down at 10–11 o'clock position to achieve full tank; Prevents normal refueling at any gas station

Repairs/costs cited: No repair attempted by owner. Owner reports avoiding overfilling after learning about stalling issue, which stops fuel from backing up when not filling to full capacity.

Faulty fuel tank shut-off float valve or check valve allows raw liquid gasoline to enter the evaporative (EVAP) vent line and fuel vapor canister instead of vapors. When purge solenoid actuates to purge canister vapors after startup, raw fuel floods engine causing over-rich mixture, stalling, and loss of vehicle control.

When: Occurs immediately or shortly after refueling to full capacity. Problem begins within days to weeks of full tank fill-up.

Symptoms owners cite: Engine stalls after full refueling; Engine floods with raw fuel; Over-rich fuel mixture detected; Raw fuel found in vapor canister and purge solenoid when inspected; Loss of power and control on highway and city roads; Stalling on turns (particularly left turns and U-turns) is especially dangerous

Repairs/costs cited: One owner replaced fuel tank and reported fuel tank, O-ring unit, vapor canister, solenoid-proportional purge, and miscellaneous pins were replaced at cost of $1,900 with 10% service discount. Dealer stated that if vehicle were in rollover accident, failed vapor canister could cause fire and reduce survival chances. Other owners replaced fuel tank at $600–$3,000. One owner had to have purge solenoid valve replaced separately but that alone did not fix the issue; full fuel tank replacement was needed.

Recalls/TSBs owners mention: Dodge acknowledged the problem in emails to owners. Issued extended warranty on fuel tank under PE13-016 (extended to lifetime coverage in some communications). However, parts shortages and backorders prevented timely repair fulfillment. Chrysler later denied warranty coverage on some VINs citing various reasons (VIN not in system, wrong build month, salvage title).

After refueling, vehicle is difficult to start or hesitates to start. Once started, engine runs rough, bucks, sputters, and may stall multiple times before settling into normal operation.

When: Occurs immediately after refueling or within the first few miles. Problem began gradually increasing in frequency from rare to almost every fill-up over time at approximately 171,000 miles in one case.

Symptoms owners cite: Difficult or hard start after refueling; Engine hesitates or fails to restart immediately; Requires flooring accelerator while cranking to start; Rough running and bucking (like 'bucking bronco') after startup; Multiple sputtering episodes over short distance; Engine shakes and trembles; Problem can last for miles after refueling

Repairs/costs cited: Owner of high-mileage vehicle (171,000+ miles) had to floor accelerator while cranking to restart after failed attempt to start following refuel. Problem worsened from rare to almost every fill-up. No repair documented.

Engine stalls suddenly without warning while driving at various speeds and road conditions, not always correlating with refueling. Loss of all electrical power including power steering, brakes, and transmission control.

When: One case began after backing out of garage (November 2013) and has increased in frequency since then. Another case occurred during highway driving and merging. Problem frequency varies and can be intermittent.

Symptoms owners cite: Engine stalls suddenly without warning; No warning signs before stall (no chugging or noises); Loss of all power including steering, brakes, and drivetrain; Stalls at idle, traffic lights, during turns, on highways, and during acceleration; Check engine light may or may not illuminate; Oil pressure warning light comes on during stall; Car can restart but loses power again soon after; Multiple stalls in short driving distance

Repairs/costs cited: One owner spent approximately $2,000 attempting multiple repairs based on service manual procedures: PCM replaced twice (first one defective), TCM replaced, battery replaced, throttle body replaced, MAP sensor replaced, ASD relay replaced, spark plugs replaced—all with zero improvement. Owner now considers vehicle unsafe to drive. No permanent repair documented.

Recalls/TSBs owners mention: Dealership unable to diagnose or replicate stalling problem in some cases. One dealership incorrectly claimed driver had parking brake engaged when no such condition existed.