Fuel tank, filler or EVAP failure on the 2005 Chrysler 300C
1 crash 2 fires 3 of the 88 reports for this failure mention a crash, a fire, an injury or a death. Those are the owner's words on the complaint form, not a verified finding, and one report can mention more than one.
When fuel tank, filler or evap failure gets reported
Owners of the 2005 Chrysler 300C report fuel tank, filler or EVAP failure at a median of 77,500 miles. A quarter of the reports come in before 50,000 miles and a quarter after 135,000 miles, from 83 reports that carried an odometer reading.
A part like this is normally expected to survive 88,000 miles. It is the 1st most-reported problem on this model year.
The mileage distribution
The reported range runs from 30,000 miles at the tenth percentile to 150,000 miles at the ninetieth, a spread of 120,200 miles across the middle 80% of reports.
A spread this wide points at use rather than design. Towing, climate, service history and city mileage all move a failure like this, so the median is a weak guide to any individual car.
12% of the dated reports were filed under 36,000 miles.
The whole distribution
| 10th | 25th | Median | 75th | 90th |
|---|---|---|---|---|
| 29,800 miles | 50,000 miles | 76,500 miles | 134,646 miles | 150,000 miles |
Read the 10th percentile as “one report in ten arrived this early”. Exact figures are shown in this table because it is the table of record; everywhere else on the site they are rounded to the precision the sample can carry.
What a percentile can and cannot tell you here
These five numbers describe the readings owners gave, in order. The median is the middle one: half the reports arrived below it. The 10th and 90th are the edges of the bulk of the distribution, and the distance between them is the part worth reading. A tight spread — say 70,000 to 95,000 miles — points at something that wears out on a schedule, and the schedule is knowable. A wide one, 20,000 to 190,000, points at a fault that hits some cars and never troubles others, which means the mileage on the listing in front of you tells you very little about your odds.
What these figures are not is a survival curve. Every reading here comes from a car whose owner filed a complaint, so the sample contains only failures: it cannot say what share of the fleet made it past 150,000 miles untouched, because those owners had nothing to report. Nor is the mileage the moment of failure — it is the odometer reading as recalled at the time of filing, which may be weeks later and is sometimes rounded to the nearest ten thousand by the person typing it.
Percentiles are shown at all only once 8 readings exist for the vehicle and mode. Below that the middle of a handful of numbers is noise wearing a decimal point, so the figures are withheld rather than dressed up.
What happens, and what it costs
Of these reports, 1 a crash and 2 a fire are mentioned. Owners write their own complaints and the agency does not verify them, so read this as what the reports say happened rather than as a confirmed count.
Putting it right typically runs $250–$1,800 at an independent US shop. That range is an editorial estimate held in this site's failure-mode catalogue, not a figure from NHTSA, and it is a repair cost rather than a diagnosis cost.
The same failure on other years
The same failure is reported on 3 model years of this car. It shows up earliest on the 2006, at a median of 70,000 miles, and latest on the 2007 at 110,000 miles.
By volume the 2006 carries the most reports, with 228; the 2005 has 88. A mode that appears across most years of a model is usually a design choice rather than a bad batch.
If one year stands out to the left, that is the year to avoid; if the whole line sits at a similar mileage, this is wear rather than a defect in one production run.
Tick median reported mileage Solid middle half of reports Faint 10th to 90th percentile Colour how bad the failure is when it happens
What owners wrote
Verbatim from NHTSA complaint narratives, trimmed for length. The mileage is the one the owner gave.
Vehicle stalls repeatedly after fueling for approximately 35 miles and sometimes takes several attempts to restart. This is very dangerous and frightening because it is never known when or where the vehicle will leave you disabled. My car has stalled many, many times, on the road, at intersections, in the middle of intersection, at stop lights, on railroad tracks, on freeway on ramps and off ramps, parking lots, and anywhere else it so chooses. I talked to mechanics and I have done some research on this and it seems to be a problem with the flat top fuel tank design, requiring the fuel tank to be replaced, but I have yet to receive notice from the manufacturer about a recall. Please look into this matter because I am concerned about the safety of myself, my family, and other 300c owners. Please help and thank you for your time!
After filling the gas tank the car will stall when driving. This happens for several miles and while in traffic. I have come close to getting into an accident on several occasions. I have looked on line and I am not the only person with this problem. *tr
When I fill up the gas tank the car stalls after 1-2 minutes. Restart and stalls again. Goes on for first 10 miles after refill. This happens after every fill up. Only way to prevent is to fill tank at 80% or less. Checked the internet (chrysler 300c stalling) and I find several people reporting the exact same problem. Clearly a manufacturing problem that can lead to some serious accidents. *tr
Also reported on the 2005 Chrysler 300C
Other fuel system problem
Other engine problem
Other powertrain problem
Shifter, linkage or stuck-in-park failure
Airbag inflator rupture
Other electrical problem
How far this goes
Complaints are voluntary, so 88 is a floor and not a count of affected cars. Mileages are typed in by owners and cluster on round numbers. And the mode itself is assigned by software reading the complaint text, which is reliable in bulk and fallible one report at a time.
Questions this page answers
At what mileage does fuel tank, filler or evap failure happen on the 2005 Chrysler 300C?
Across 83 owner reports that included an odometer reading, half were filed by 77,500 miles. A quarter were filed before 50,000 miles and a quarter after 135,000 miles. These are the mileages owners reported when they complained, not a prediction for any individual car.
How common is fuel tank, filler or evap failure on the 2005 Chrysler 300C?
88 reports have been filed with NHTSA, about 1.5 per 1,000 vehicles. Complaints are voluntary, so this is a floor rather than a count of affected cars.
What this is and is not. These are the mileages at which owners chose to complain to a federal agency, which is not the same as the mileage at which the part fails on every car. It skews toward failures that happened outside warranty, cost real money, or frightened someone. It is still the only public dataset that carries failure mileage at all, and the shape of a few hundred readings is informative even when a single one is not. Methodology · JSON · this failure on other cars
Source Owner complaints and recall records published by the US National Highway Traffic Safety Administration, model years 1996–2027 Figures rebuilt Published by AtWhatMileage How every figure is computed