2005-2006 TJ LJ - Fix for gas overflow issue - Page 2 - Jeep Wrangler Forum
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Old 05-10-2013, 05:34 PM   #31
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Absolutely worked!! I took it to my mechanic buddy at the Chevy dealer and he knew exactly what to do without explaining. He cut out the flapper and put in the jeep hose on Monday and today I was finally able to fill up and not a drop on my fender or ground or anywhere!! He probably knew all about it considering the part is from a Chevy Trailblazer

I recommend the stuffing of the flapper in the jeep hose rather then trying to bend a straight hose and cut it and all that non sense. You won't have problems down the road like other members have of kinking and what not.

Well worth the $30 part for this mod!! Stupid chrysler should just make there own jeep hose with a flapper in it!

Works perfect and now I don't have to look like an idiot filling up gas

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Old 05-13-2013, 10:39 AM   #32
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Ordered mine today and hope to fix it over the weekend.

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Old 05-19-2013, 03:56 PM   #33
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Fixed it Friday and filled up Friday night. Worked like a champ.
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Old 05-19-2013, 06:08 PM   #34
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Quote:
Originally Posted by clarkkent View Post
Alternatively could you just fill up at stations with no ethanol?
We have 3 gas stations here that are ethanol free which is what I use and it still overflows I'll just pay the $30 to make it stop
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Old 05-19-2013, 06:45 PM   #35
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Yeah I didn't care what the cause, just glad to find a fix. Works great.
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Old 06-13-2013, 05:54 PM   #36
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Does anyone have a pic of the fill hose in an 05 jeep? The guy before me put a 3 inch body lift and in takin it off and he reallllllly butchered it up
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Old 06-13-2013, 06:55 PM   #37
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Here is the one I took off my '05 when I did the Hoppe mod GM hose.
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Old 06-13-2013, 07:09 PM   #38
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Boy, mine looks nothing like that now lol
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Old 09-07-2013, 10:37 AM   #39
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Installed the GM part and filled up today. Works as advertised!
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Old 01-17-2014, 11:15 PM   #40
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I also did the GM filler tube. IT WORKS GREAT! Not a drop spilled
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Old 01-19-2014, 08:45 PM   #41
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I did it too. I've filled up twice and this works great! Got mine from GM performance parts
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Old 01-19-2014, 11:44 PM   #42
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i have a question my filler tube doesnt really spit out fuel. what it does do is always cause the pump to click off even when im start fueling from empty. sometimes it takes me 20min to fill my darn tank up. will the new filler tube fix my problem as well?
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Old 01-20-2014, 12:06 AM   #43
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Here are 2 links that should help. (having an LJ should make this easier)


Gas overflow

Can’t fill the tank
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Old 01-20-2014, 08:35 AM   #44
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mine is done too.. more more splashing out .. love it..
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Old 01-20-2014, 11:33 AM   #45
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Quote:
Originally Posted by RUBI 4 MY MRS
Here are 2 links that should help. (having an LJ should make this easier) Gas overflow Can’t fill the tank
Thanks I appreciate that. That was what I was looking for.
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Old 03-24-2014, 12:23 PM   #46
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I did the GM hose in my LJ a couple years ago. Great at first, then eventually a kink settled in. Maybe I didn't cut enough off? Since I have no BL, my hose needed to be short but I didn't want to go too short! After the kink settled in, the only way to fill my tank was to run the pump as slow as it would run... no where near the first catch on the auto-fill! Four people would get gas and leave at the next island before I could get my ~15 gal.

Finally this weekend I removed my GM hose, dissected it and removed the flapper assembly.
Soaked my old stock hose in hot water... put a bit of waterless hand cleaner on the inside as a lube, aligned the flapper inside the bottom of the hose, and slipped in a 7/8" deep well socket, back side against the flapper. I held the hose, and slammed the socket against the workbench. Three times like that set the flapper assembly deep enough into the hose... into the narrow part of the hose, but still in the lower half.
I cleaned and dried the hose, verified that the flapper still worked easily by breathing into the hose.

I've also had some problem with the float coming up in the tank filler neck, and getting stuck.
I took a 3/32" piece of stainless TIG wire and forced the float to the bottom of the fill neck.
I cut the stainless wire about 1/2" longer than the total length of the tank fill neck... then bent over the last 1/2", 180░. I flattened the bent over end with a ball peen, then filed all edges smooth. I slipped the wire into the tank neck, holding the float down. I hooked the bent end over the top of the tank filler neck, verified it would stay in place/not shift, and that the rubber fill hose would still fit down over the tank neck with this wire hooked onto the neck. I then installed my modified original filler hose. I made certain that the wire did not extend on the outside of the neck too far... I needed the hose clamp to seat the hose at the base of the neck without interference.

I realize that this defeats a safety feature... the float/ball check would seal off the tank in the event of a roll over. But when a safety feature doesn't work as designed and prevents normal operation of the vehicle (such as normal filling of the fuel tank), then it needs to be circumvented. Especially since the manufacturer has not provided a solution. Besides, the flapper assembly will take it's place in the event of a rollover.

So now it's all back together,,, and I have 3/4 of a tank of gas. I'll let you know how it works when I fill up next time... probably next week.
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Old 07-26-2014, 09:11 AM   #47
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I have the GM hose on my workbench waiting to go into my 05 Rubicon. Cant wait to get back in town and make this problem go away!
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Old 07-26-2014, 03:43 PM   #48
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I just ordered the part form Amazon so I should have it next week. Has anybody done a SWB TJ? I have no problem getting my hands dirty, I have a goos set of tools and I was hoping someone with a similar model may have some suggestions. Is it wise to try to just swap out the flapper from the GM hose or will the mod be a permanent fix?
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Old 07-26-2014, 04:38 PM   #49
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I think that putting the flapper into the OEM hose is the way to go & the OP agrees (posts #1 & # 28). I haven’t swapped the flapper in my OEM hose since it has worked great in the GM hose for more than 2 yrs but others have had some problems including one where the GM hose partially collapsed on the inside & blocked flow. Many have been installed on SWB TJs but if you just put the flapper into the OEM hose you have no issues for sure. Getting the clamp off at the tank is probably the most difficult part. On reassembly reposition it for easier access in case you ever need to remove it.

Original post w/photos
'05-'06 gas overflow fix - JeepForum.com

Flapper inserted in OEM hose Posts 328 & 330
'05-'06 gas overflow fix - Page 22 - JeepForum.com

Problem with GM hose
Gas overflow fix hose problem with GM hose - JeepForum.com
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Old 07-26-2014, 05:00 PM   #50
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Thanks so much for the info. I am fairly new to this Jeep ownership thing and I have been enjoying every bit of it, it is just so frustrating at the pump and the damage is already done to the finish on my flares.

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