2005-2006 TJ LJ - Fix for gas overflow issue - Jeep Wrangler Forum
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Old 03-03-2012, 12:11 PM   #1
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2005-2006 TJ LJ - Fix for gas overflow issue

I came up with a cheap and easy fix for the 2005 - 2006 TJ / LJ fuel overflow problem. To clarify, I'm referring to the issue of gas "burping" out of the filler neck right after the pump clicks off when the tank is full. The cause is the ethanol in the gas causing plastic parts in the Inlet Check Valve (ICV) to bind and not close quickly enough to prevent fuel back-splash when full. See link below.

'05-'06 gas overflow fix - JeepForum.com

Owners of 2005 - 2006 TJ / LJ Wranglers were left up $#!t creek by Chrysler and the NHTSA on this one. '07 and newer got a warranty extension - NHTSA closed the investigation taking the heat off Chrysler - '05-'06 owners got the shaft. There's almost no point I filing a complaint with NHTSA any more because our complaints were already dismissed as "Internet hype".

You can either jump through Chrysler's flaming hoops and beg for some "goodwill" assistance with a $1200 dealer repair (parts & labor to replace the whole tank) which means you still shell out a $200 "co-pay", or you can order a <$30 GM hose with a flapper style check valve and be done with it. This is how GM fixed the exact same problem in the Trailblazers, Envoys, Bravadas, etc.

Hope this helps.

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Old 03-03-2012, 01:31 PM   #2
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part number?

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Old 03-03-2012, 01:39 PM   #3
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Quote:
Originally Posted by RUparrothead View Post
part number?
The part number and write-up are in the linked JF thread.
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Old 03-04-2012, 07:17 AM   #4
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Gotcha. Thanks!
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Old 03-24-2012, 02:06 PM   #5
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Quote:
Originally Posted by SHoppe715
I came up with a cheap and easy fix for the 2005 - 2006 TJ / LJ fuel overflow problem. To clarify, I'm referring to the issue of gas "burping" out of the filler neck right after the pump clicks off when the tank is full. The cause is the ethanol in the gas causing plastic parts in the Inlet Check Valve (ICV) to bind and not close quickly enough to prevent fuel back-splash when full. See link below.

'05-'06 gas overflow fix - JeepForum.com

Owners of 2005 - 2006 TJ / LJ Wranglers were left up $#!t creek by Chrysler and the NHTSA on this one. '07 and newer got a warranty extension - NHTSA closed the investigation taking the heat off Chrysler - '05-'06 owners got the shaft. There's almost no point I filing a complaint with NHTSA any more because our complaints were already dismissed as "Internet hype".

You can either jump through Chrysler's flaming hoops and beg for some "goodwill" assistance with a $1200 dealer repair (parts & labor to replace the whole tank) which means you still shell out a $200 "co-pay", or you can order a <$30 GM hose with a flapper style check valve and be done with it. This is how GM fixed the exact same problem in the Trailblazers, Envoys, Bravadas, etc.

Hope this helps.
OMG! This works. I was quoted $1310 this morning by a jeep dealer to fix it. As i was driving home cursing the powers that be i made a stop at a gm dealer that had this hose. $28 later and it worked! Only problem now is the $3.99 for the gas. Bastiches!
Thanks for the tip.
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Old 03-24-2012, 05:35 PM   #6
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I've tried to find that part online to order it but I can't find it. Anyone know where to order it at?
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Old 03-24-2012, 05:54 PM   #7
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I fixed mine without spending a cent. I just let off before its full and only pull the handle halfway to top it off. Works every time.
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Old 03-24-2012, 06:33 PM   #8
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Good find! I'll try this out as soon as I can. I'm tired of calculating how much fuel might fit in the tank before it pukes out.
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Old 03-26-2012, 12:06 PM   #9
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Just Filled up and not a Drop Spilled over.
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Old 03-26-2012, 12:10 PM   #10
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Quote:
Originally Posted by rubicon2 View Post
i fixed mine without spending a cent. i just let off before its full and only pull the handle halfway to top it off. Works every time.
+1
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Old 03-26-2012, 03:43 PM   #11
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Just ordered my hose/check valve, should be here in a few days!
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Old 03-26-2012, 05:30 PM   #12
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Quote:
Originally Posted by div4gold
I've tried to find that part online to order it but I can't find it. Anyone know where to order it at?
I called a gm dealer. It was on backorder but he was able to tell me if there was another dealer in the area that had it. If not go to gm parts direct website and type in part number 15........ That is in the photo.
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Old 03-26-2012, 05:39 PM   #13
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Yea, i could have save $30 and played with the has pump every time i fill up. The problem is my wife and daughter drive it at times and i cant see them playing with the gas pump to try and guess when to stop. $30 and 45 minutes of my time is worth it.
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Old 03-26-2012, 05:44 PM   #14
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Btw. Gm parts direct has the part for $16. Not sure what shipping cost is.
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Old 03-30-2012, 07:06 PM   #15
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06 Unlimited Rubicon that had the problem. I bought the GM hose and it works. I've tanked up twice now and it operates as it should. I had the dealer do it; $30 for the part and 1 hour labor.
Kudos to the guy that figured it out.
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Old 04-02-2012, 01:05 PM   #16
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Alternatively could you just fill up at stations with no ethanol?
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Old 04-02-2012, 01:13 PM   #17
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Originally Posted by clarkkent View Post
Alternatively could you just fill up at stations with no ethanol?
They exist? I thought they were just a myth.

And its not the act of using a pump with ethanol, its what the ethanol does to the plastic or what ever the part is made out of over time. thats why it works for a while, then happens again if you do the same replacement fix.
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Old 04-02-2012, 06:37 PM   #18
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Received my GM hose with "flappy valve" today, will report back with results after install.
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Old 04-02-2012, 09:50 PM   #19
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Alternatively could you just fill up at stations with no ethanol?
If I knew where one of those was around here, I'd have been using that anyway. But if I knew where one was, wouldn't it be too late at this point? $30 is money well spent.
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Old 04-03-2012, 12:35 AM   #20
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Ethanol-free gas stations in the U.S. and Canada

Is the website I use to find stations that are ethanol free.

I was actually paying attention tonight and they even have a sign up that says, 'no ethanol.'

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Old 04-07-2012, 07:02 PM   #21
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Installed new gas hose, ended up with a small kink just like in posted pics. Not too bad though.
First fill-up today, at a pump with good, fast flow. Pump clicked off perfectly! Totally full tank, and not a even drop spit back out!

Almost can't wait to fill up again...Almost.
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Old 04-14-2012, 08:04 PM   #22
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Filled up again, cost a million bucks, but NO spit back! Super coolio!
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Old 04-15-2012, 08:58 AM   #23
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Thank you for posting this solution! The gas-filler problem is one of only two things about me Jeep that really bug me. This will be the best $30 I've spent in a long time.
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Old 04-15-2012, 09:04 AM   #24
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very nice work!
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Old 11-09-2012, 06:48 PM   #25
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Has anyone simply removed the valve from the stock hose and put the hose back on?

J
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Old 01-01-2013, 08:29 AM   #26
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I have a 2010 with this problem, what can I do?
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Old 01-01-2013, 10:15 AM   #27
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use your warranty
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Old 01-05-2013, 10:19 AM   #28
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Has anyone simply removed the valve from the stock hose and put the hose back on?

J
Yes. A few have cut the flapper valve out of the GM hose and inserted it into their OE Jeep hose. Works great if you can't get the kink out of the straight one.

It's a long read by now, but there's a few replies in the JF thread talking about how they pushed the flapper into the Jeep hose with a socket. Some used heat, lube, or a combination of both.

The most important part to remember is getting the flapper's hinge oriented in in the hose right and getting the valve itself as horizontal as possible.
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Old 03-31-2013, 10:45 AM   #29
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Add me to the list of those who replaced my Jeep filler hose with the GM filler hose. Just like the other write ups I had to trim mine several times to get it to stop kinking. But once I had it trimmed short enough it fit almost perfect. As soon as I was done I went down to the gas station and filled it on the fastest setting and no splash back . Count me in as 1 happy Jeeper.
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Old 05-07-2013, 10:33 PM   #30
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Yall just saved my fender flare, Gotta get on this soon as i can

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