I realize this is an old topic but I don't believe there are any recent posts about it and I think a reminder about this great program is good for newer 300 owners. I would just like to share my experience and path that led me to getting the issue resolved. Hoping it may help someone else.
It's been about two months since my fuel tank was replaced under Chrysler's X53 lifetime fuel tank warranty. I couldn't be more happy with the results and Chryslers handling of it. When I first purchased my 2006 300C SRT8, a little over a year ago, I loved the car. Just an amazing car from top to bottom. The car had just over 100k miles on the odometer, but you can tell it had been very well taken care of, and was owned by an older female (??) driver that didn't drive the car hard. Well above average condition, with everything working as it should. The one detail I found out after buying was not quite right was that it would stall every now and then. No warning, no stumbling, just as if I had turned the ignition switch off. It always started right back up like it never happened. It only did it after idling for a little while. Sitting at a red light for an extended period of time would increase the possibility of it happening. Not always, and no way to reproduce the stalling with any degree of certainty, except filling the fuel tank. After a fillup there would always be a stumble and die after departing the pump. Then it would go away and not come back till next fill up which I learned to avoid doing for the time being. These seemed to me at least to be two separate issues. Stalling after idling for a long time had no link to filling up and it was very sudden like turning off the ignition. Always start right back up without stumbling. The issue at fill up was different. Then it would stumble a little, then die, sometimes even in motion as I pulled away from the pump. Starting back up often was accompanied by a bit of a stumble then all is good, with no further issues. For that reason, I discounted the fuel tank issue as being the only possible problem. Always fill up with 93 octane, no codes present. Tried changing the spark plugs to some cheaper than OEM - NGK LZTR5AGP. Yeah, those made it worse. It would stall after running 10 seconds and would not stay running long enough to drive. Spend the 8 dollars per plug to put the OEM plugs (8x16=128 dollars!) back in it, and back to square one. (found out the ones I took out originally had just been replaced - ouch) Checked fuel pressure, ran diagnostics with my OBD scanner while running - recording real time data. Weird. All data looked good, then suddenly when stalling, data just stops, like when turning off ignition. Checked all grounds on the body and engine compartment. Checking wiring harness. Battery. All good.
Mostly out of desperation and being out of things to check, I called Chrysler (800-247-9753) to see about this fuel tank thing. I was a Chrysler, Dodge, Jeep service writer and technician 20 years ago so I know certain things help in making this call. (some things never change) I recommend calling Chrysler as opposed to calling your local dealer first. It will expedite things - trust me! Have your vin number and mileage handy. Even though the mileage is unlimited on this warranty, they need it to open the case file. Mention the problem and refer to the "X53 fuel tank warranty". It will help them find it quicker. After looking up my vin the person confirmed that my vehicle was affected by the warranty. I fully expected that at least my fuel tank would be replaced and fix the stumble and stall after fill up but the stalling after idling for long even on low fuel would not be fixed. The man asked me for my preferred dealer to take it to and if I had a specific service writer I deal with, which I did. I typically do any work needed on my SRT myself as it is out of warranty for the most part, but my wife's Challenger is still very much under warranty so we have a good relationship with our Dodge dealer. Called my girl Erin at Allstar Dodge, and told her what was going on. She promptly scheduled for me to bring it in in a couple of days and also informed me my long awaited passenger airbag replacement part was finally available! Yay! When dropping off the car, just for the heck of it, I asked about a rental in the meantime since we always get one for my wife's car whenever they have to keep it longer than a day. She told me she would have to confirm the problem first and it might be a day. Long story short, the next day Erin called and said yes, the issue is confirmed, and set me up with a rental. Only had it one day because they overnighted the fuel tank. Picked it up a couple days later - drove to the place across the street - filled it up - and NO MORE STALLING. Over the months, I have found the other issue was gone as well. It is all related and it is not necessarily only affected after fill up. Very happy with the results. And now for the best part - a day later a lady called me from the "Chrysler SRT division" to ask if I was happy with my experience and wanted to make sure I didn't need anything else. I said, nope, as happy as I can be. She said well I am going to give your 3 years of oil changes just because we at Chrysler are sorry for the inconvenience. Wait, what? Do you mean 3 oil changes? No she said, 3 years worth of oil changes. Twelve oil changes in all. I asked her if she was aware that my car only takes fully synthetic, very special oil, and she said yes. Wow, I am blown away by that. I don't know if it is just because SRT owners get special treatment or what. Maybe it was just my lucky day. I don't know, but my girl at Allstar confirmed that my oil changes are already in the system and to be billed to Chrysler. I have been a Mopar guy since my days of being a tech and service writer but this just makes me feel even better about it. Not to mention my SRT8 is the most amazing car I have ever owned, and I have owned a lot different vehicles. I have since done a number of mods to it and can say - it is wicked fast, and they only car I have ever been afraid to floor the gas on.
