NHTSA Complaint #11714342 — 2007 DODGE MAGNUM

My 2007 Dodge Magnum RT (5.7L Hemi) suffers from a dangerous engine stall immediately after refueling. The vehicle is equipped with the 19-Gallon Fuel Tank. When refueling, if the tank is filled to capacity, the engine stumbles and shuts off completely upon leaving the gas station. This stall occurs without warning in traffic, causing an immediate loss of power steering and power braking assistance, which creates a severe risk of a collision. This is the identical failure addressed in NHTSA Investigation PE13-016 and Chrysler Warranty Extension X53. The internal Multifunction Control Valve (MFCV) is defective; the float has swollen and remains stuck in the "open" position. This allows liquid fuel—not just vapor—to flood the EVAP system and the engine intake. I have already replaced the charcoal canister and purge valve, but the stalling persists, proving the defect is internal to the fuel tank assembly. Despite the 2007 models using the same defective tank design as the 2005-2006 models, Chrysler has excluded my year from the lifetime warranty extension. I am reporting this because it is a safety hazard.