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Old 11-17-2012, 10:21 AM   #1
TalkIsJeep's Avatar
Join Date: Mar 2011
Location: Southington, CT
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Having trouble gassing up..

So I lifted my LJ 2-3 months ago, and I know I had to mess with the filler hose for the tank, but I've never had problems with it until today. AFAIK it's a somewhat common problem for wranglers to overflow when filling the tank, instead of shutting the pump off, but mine was overflowing when my gas light was on. I started pumping, and the pump continually shut off every dollar or so, like it would if the tank was full. When I got to about 6 bucks, it spit a little out, which I found weird. I babied the pump to 10 dollars, no problem..then just a little over 10 bucks a lot shot out. At this point, I've gone from gas light on to pumping about 2.xxx gallons in. Any ideas what could be causing this? I'm not sure if weather could effect the hose in any way, but it's recently been dropping to the 30-40's during the day and 20ish degrees at night..

Hoping to get this solved soon so I don't have to keep putting $80 in the Jeep and $10 on the ground..Thanks guys!

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Old 11-17-2012, 01:01 PM   #2
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Just an update: I went to fill up today at a different gas station and it went off without a hitch. Maybe it was the pumps at the gas station? Either way, I'm happy now.. I'll avoid that place in the future just in case.

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Old 11-17-2012, 01:40 PM   #3
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Our LJ has one of those issues as well. The pump typically stops every dollar or two. It takes a few tries to get the "sweet spot" where it won't keep stopping. I find what works best is to lift the nozzle up when inserting, then shove it as far in as it will go. That's the trick for ours. Try playing around with angles and such to see if you can find what works best for your LJ. The '05-'06 TJ/LJ's seem to all have some issue when pumping gas. Thankfully, ours doesn't overflow (unless it's full and we think it's just doing it's spasming thing, so we try to pump more in and it overflows... Lol). There's a defect in the gas tank that Jeep has never bothered to fix. You can get it replaced, but you end up with a new tank with exactly the same problem.

I found a link just yesterday where you can fill out a form to complain about just this sort of defect. An organization investigates because it's a safety hazard to be spilling gas all over the place. I'll have to go find it again. Will post for you later today.
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Old 11-17-2012, 04:38 PM   #4
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A combination of nozzle angle/depth and low pump speed works for me. It could be my imagination but certain pumps at the same station are worse than others.
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Old 11-17-2012, 08:27 PM   #5
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The 2005 and 2006 Jeep Wrangler TJ models have an issue with the fuel system. The fuel tank has a valve called the ICV that gets stuck and there is no way to fix it. It is a flaw in the design of the tank. This stuck valve causes the fuel to not react correctly when the fuel reaches the full point and doesn't trigger the pump correctly to stop the fuel from pumping. This causes the pump to keep pumping and spews fuel out onto the side of your Jeep Wrangler and on to the ground.

So far there has not been any corrective action taken by Jeep to fix this issue for our model years. They have however fixed other model years with the same problem. The fix requires a completely new tank with a better designed ICV valve. Currently you can buy a new tank for your Wrangler but it will cost somewhere around $900 and it is the same poorly designed tank you already have.
Apparently, there is a class action lawsuit about this that was filed in 2011. Haven't heard an update on it. Here's the website where you can file a safety complaint: Office of Defects Investigation

Anyone with this problem should file a complaint. The more complaints filed, the more likely the issue is to be investigated so Jeep can come up with a fix and replace our faulty tanks. Sure would be nice. =)
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Old 11-17-2012, 09:45 PM   #6
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Mine only works well if I turn the gas handle to almost a quarter of the way over. My hand ends up being at almost 3:30 on the clock
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Old 11-18-2012, 03:23 PM   #7
Join Date: May 2011
Location: Great Falls, MT
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On mine I have to put the nozzle all the way in and then pull it about halfway back out. If it's in all the way it stops all the time.

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filler hose , fuel , gas , spilling , trouble

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