NHTSA Complaint #10701405 — 2004 DODGE RAM 1500

THE TRUCK STALLS AT IDLE OR LOW SPEEDS AFTER REFUELING. IT HAPPENS EVERY TIME. IT IS DANGEROUS BECAUSE THE POWER STEERING GOES OUT AND THE TRUCK IS VERY DIFFICULT TO CONTROL. IT HAS HAPPENED AS I AM ENTERING OFF-RAMPS AND PROCEEDING THROUGH INTERSECTIONS. THE PROBLEM IS THE VAPOR/LIQUID SEPARATOR VALVE LOCATED AT THE TOP OF THE FUEL TANK. THE VALVE IS DESIGNED TO PREVENT LIQUID FUEL FROM ENTERING THE CHARCOAL CANISTER/EMISSIONS SYSTEM. WHEN THE VALVE FAILS, LIQUID GAS CAN ENTER THE LINE AND FILL THE CHARCOAL CANISTER. AFTER REFUELING, THE PCM ON THE VEHICLE DETECTS A CHANGE IN FUEL LEVEL. THEN, WHEN THE ENGINE MEETS CERTAIN TEMPERATURE AND DRIVING CRITERIA, THE PCM ISSUES A PURGE COMMAND TO THE CHARCOAL CANISTER TO REMOVE THE STORED GAS VAPORS. IT?S AT THAT POINT THAT ALL THE LIQUID GAS IN THE LINE GETS SUCKED INTO THE CHARCOAL CANISTER. THE PCM EXPECTS TO SEE GAS VAPORS ENTERING THE INTAKE MANIFOLD AND IT IS PREPARED TO ADJUST AIR/FUEL MIXTURES TO COMPENSATE. HOWEVER, IT IS NOT PREPARED TO SEE LIQUID GAS COMING INTO THE INTAKE. THAT?S WHAT CAUSES THE ENGINE TO STALL. UNFORTUNATELY, THE ONLY FIX IS TO REPLACE THE ENTIRE GAS TANK. CHRYSLER DOES NOT SELL THE VAPOR/LIQUID VALVE AS A SEPARATE UNIT. ONCE THE TANK IS REPLACED AND THE CHARCOAL CANISTER PURGED, THE PROBLEM GOES AWAY. THIS PROBLEM IS WELL-KNOWN TO CHRYSLER ACROSS A BROAD RANGE OF VEHICLES, INCLUDING PICKUPS, MINIVANS AND SUVS. CHRYSLER SETTLED WITH COMPLAINANTS ON SOME MODELS AND YEARS BY AGREEING TO EXTEND THE WARRANTY TO LIFETIME, BUT REFUSES TO ACKNOWLEDGE THE PROBLEM OUTSIDE OF THOSE VEHICLES. I AM LOOKING AT A $1,300 REPAIR BILL FOR A KNOWN DEFECTIVE AND UNSAFE PART, THE REPLACEMENT FOR WHICH CHRYSLER REFUSES TO SELL SEPARATE FROM THE GAS TANK ITSELF. I WOULD BE DEEPLY GRATEFUL FOR ANY ASSISTANCE YOU MAY PROVIDE. *TR