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Old 03-15-2010, 07:33 PM   #1
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Overflow at the gas pump

Hey all, another question from the newbie.

When I fill up my tank at the gas station, the auto fill won't click off until the gas tank is overfilled, and sprays out, then runs down the side of my jeep. It doesn't matter if I use their auto fill notches and walk away or hold it by hand, the gas wont click off until the tank is overflowed. I have been having to guess how much gas I need and stop before I get to that point to avoid the overflow. Is this normal for a 2006 TJ, or is there a fix for it?

Thanks!

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Old 03-15-2010, 08:32 PM   #2
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Strange... I have the opposite problem! Mine always clicks off way before it is full. I usually have to pull it out half way before it will stop clicking off. Do you put the nozzle all of the way in or half way in?

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Old 03-15-2010, 08:52 PM   #3
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mine does it as well (05 X), everytime without fail if i'm not paying attention to stop before it gets close to full. this has been discussed before in another thread, do a search and you will find some more info on it too!
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Old 03-15-2010, 09:20 PM   #4
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I have just noticed my YJ doing this when i fill up as well... just a little bit of gas flows out at the end when it auto fills... its minimal but it does happen... idk if my overflow hose came off or is leaking or what but mine has started to do it too... i will be away from it for a few days but i will check it when i get home but like i said mine is a YJ not TJ
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Old 03-15-2010, 09:22 PM   #5
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My LJ has done this ever since I bought it. It's a real pain in the butt.
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Old 03-16-2010, 01:17 AM   #6
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mine does this also have to watch it, mainly at BP stations but not at Shell??
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Old 03-16-2010, 06:30 PM   #7
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Old 03-17-2010, 12:54 AM   #8
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x2 my 05 LJ always does this. Depending on the angle and the pump it will keep clicking over and over or never stop and spill gas everywhere. Just got used to figuring how much gets me to full and listening to it..
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Old 03-17-2010, 03:06 AM   #9
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My 06 TJ does it as well...submitted a complaint.

My 08 Nissan Frontier did it also....
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Old 08-15-2010, 08:03 PM   #10
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05 LJ spills everywhere! Sucks!
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Old 08-15-2010, 08:11 PM   #11
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Quote:
Originally Posted by dylan View Post
x2 my 05 LJ always does this. Depending on the angle and the pump it will keep clicking over and over or never stop and spill gas everywhere. Just got used to figuring how much gets me to full and listening to it..
X2... my 07 JK sahara does this all the time... the best way to stop it is to listen to it and stop just as it sounds like its about to overflow...

p.s. keep an eye on the gallons pumped, it will usually help give you a guess on how much gas to pump.... good luck!
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Old 09-15-2010, 10:09 AM   #12
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Same here. Picked up an '07 Sahara about 6 weeks ago. Doesn't matter which gas station I use or the angle and depth the pump is in, it ALWAYS overflows. Frustrating:/
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Old 09-15-2010, 10:26 AM   #13
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Same, my 05 TJ started doing it when I got back from my deployment. It sat for 7 months, but I'm not sure if that had anything to do with it or not. I've seen some folks say it's due to a stuck valve in the tank and the only way to fix it is to replace the tank. But thats unverified.
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Old 09-15-2010, 11:40 AM   #14
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Had an 07 and it always overflowed. So far our 2010 has not had the problem.
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Old 11-08-2010, 02:56 PM   #15
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My 2006 Wrangler X 6 cyl developed this same fuel spill on fillup problem for the past year or so.
I just lived with it .

Then , my check engine light came on , code P0456.

Took it to the dealer as it was still under warrantee.

After they replaced the fuel cap,then the fuel lines, they discovered that valve on top of the fuel tank was sticking open .

They had to replace the fuel tank to replace that valve.
This fixed the check engine light problem .

However replacing the tank also fixed the fuel spill on fillup problem , hooray!
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Old 11-09-2010, 06:40 AM   #16
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It is what they do. You have to listen to it and not leave it pumping on its own.
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Old 11-09-2010, 06:45 AM   #17
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i live in NJ, so i just unzip the window and say, "fill it regular, please."
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Old 11-09-2010, 08:10 AM   #18
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Aw... I bet the attendants hate that. I've seen how crazy it can spray out. Not paying attention and next thing you know, gas all over you.
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Old 11-09-2010, 09:17 AM   #19
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Quote:
Originally Posted by cruisesinc
My 2006 Wrangler X 6 cyl developed this same fuel spill on fillup problem for the past year or so.
I just lived with it .

Then , my check engine light came on , code P0456.

Took it to the dealer as it was still under warrantee.

After they replaced the fuel cap,then the fuel lines, they discovered that valve on top of the fuel tank was sticking open .

They had to replace the fuel tank to replace that valve.
This fixed the check engine light problem .

However replacing the tank also fixed the fuel spill on fillup problem , hooray!
I agree with cruisesinc my 05 TJ just started having this issue a month ago. This is my second TJ and never had this issue before. I did not get the fault code but the gas is definately trying jump out of the tank at the pump -
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Old 04-17-2011, 03:59 PM   #20
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I’m hoping for another push to get the TJs included for extended gas tank warranties like the ’07 &’08 JKs recently got. I have over 325 handles of TJ owners that have complained of fuel spill out when they fill up. These come from the various threads on various forums. Some have filed complaints, some I’m sure haven’t. Let’s all file or re-file. I will continue to add to my list.

If anyone has this problem but has not posted, please do so. We need to know how many TJs are actually having this problem. I know there are always suggestions for work-arounds but please don’t post them here. We want to actually get this resolved.

To help spread the word, I made up some business size cards & carry several everywhere I go. Anytime I see a TJ in a parking lot, I leave one on the windshield. It just asks them if they are having this problem & if so directs them to one of these forums. I hope others will do the same.

The most discouraging thing is that Chrysler has more than doubled the price of replacement tanks. If anyone can verify that they have improved or redesigned the inlet check valve (ICV) let me know. It was supposed to have happened in Feb.

Check valve (ICV) manufactured by Alfmeier.

Also worth noting that while the ’03-’06 TJ tank now lists for $914.00 (last previous price I could find was $427.00), the JK tank lists for $192.00 (2dr) & $265.00 (4dr). All from mopar-wholesale.com (their prices are $630.20, $132.25, & $182.85 respectively)


..and here is the PART NUMBER to the latest Fuel Tank:

52059617-AG COST: $341.60 RETAIL: $427.00

.

Item Number MSRP Core Price Price
52059617AG $914.00 $0.00 $630.20
Fuel system - Fuel system components - Fuel tank
Fuel tank - 2003-06 2005 - 2006


Item Number MSRP Core Price Price
52059718AH $192.00 $0.00 $132.25
Fuel system - Fuel system components - Fuel tank - 2 door
2 door 2010 - 2011

Item Number MSRP Core Price Price
52059729AG $265.00 $0.00 $182.85
Fuel system - Fuel system components - Fuel tank - 4 door
4 door 2009 – 2010
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Old 10-29-2011, 11:55 AM   #21
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I have filed my complaint. My 2005 TJ overflows every single time I fill up. The pump never cuts off until there is gas on the side of the vehicle and on the ground. I try to listen to the fill up but the gas stations are normally too noisy to hear the fuel getting close and I don't want to have my face too close to the spit back.
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Old 10-29-2011, 01:33 PM   #22
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That's odd. Knowing how pump nozzles work, I can only guess that the angle of the fuel neck is letting the nozzle "ride up" in the neck and the fuel spills out before it reaches it. Are you guys making sure the nozzle is in the neck as far as it can go? I haven't had any trouble with mine (yet).
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Old 10-30-2011, 12:30 PM   #23
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Wranger fill up spill problem.

To fix the Wrangler spill over problem, the fuel tank must be replaced. There is a small valve built into the top of the tank , that sticks . Not sure if it is sticking open or closed, but it is the cause.
Luckly I had mine replaced by Chrysler 1 week before the warantee expired.
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Old 10-30-2011, 12:41 PM   #24
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no problems for me...im too poor to fill up my jeep
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Old 10-30-2011, 05:35 PM   #25
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Stick your winky in it and you can find out
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Old 10-31-2011, 09:09 AM   #26
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I have a 2006 Wrangler TJ and same thing often happens to me. I try to listen and just ease off when it sounds like almost full.

Thought it was only me and the pump I use till I saw your post.
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Old 10-31-2011, 11:39 AM   #27
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Even though 2/3rds of all complaints filed with the NHTSA by owners of '05 & '06 TJs are for this problem & Chrysler knows the design of the check valve that causes it is to blame, we can't get a recall or even an improved design (one has been promised but hasn't happened as far as I can tell). File your complaint by clicking on the link below.

Does your TJ’s gas tank overflow at the pump? SUBMIT COMPLAINT HERE!

See what others have found. Enter your yr & model at Consumer Automotive Safety Complaints & Car Problems - ARFC
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Old 10-31-2011, 02:05 PM   #28
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This issue is not going away. Since 8-3-2011 (about 90 days) of the 34 new complaints for the ’06 TJs, 28 have been for fuel spitting out. For the ‘05s - 27 new & 22 for this. That is 50 new complaints in 90 days.

Here is the latest:



10-31-11

There are 397 complaints filed for the 2006 JEEP WRANGLER +34

Fuel System Gasoline (267) +28

Fuel System Other (7) -1

There are 341 complaints filed for the 2005 JEEP WRANGLER +27

Fuel System Gasoline (233) +22

Fuel System Other (3) 0

69.0% of all complaints (274/397) for ’06 & 69.2% (236/341) for ’05 are fuel related & most are for this fuel spit-back problem.

Here is a bulletin: Chrysler claims that the problem is exposure to ethanol (above 10%). They also claim they are going to re-design or re-spec the valve. Well there are already 20 complaints filed on 2010 JKs - the first one in Jan., 2010. At least one complaint was from the VERY FIRST time they filled up!

Does your TJ’s gas tank overflow at the pump?SUBMIT COMPLAINT HERE!
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Old 10-31-2011, 02:46 PM   #29
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Stick your winky in it and you can find out
But the hole's too small...
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Old 11-05-2011, 06:16 AM   #30
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Have a 2006 Wrangler did the samething took it to the dealer hate to tell you this but they replaced the gas tank. They told me its a common problem but no recall has been done yet.

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