I found that if I tilt the nozzle handle up a lil bit with it still all the way in and keep filling it won't overfill. I start the tilt when it gets close to full, never had a problem since I started doing it this way.
Sure there are work-arounds but the fact is that you have a stuck check valve in the tank. As I read the manual, it has 2 purposes. 1 to prevent gas spill out when filling up & 2 to prevent spills in rollovers. Many of us are aware of #1, we better hope we don’t encounter #2. Anyway, you should consider a complaint to the NHTSA. It has worked for the JK owners. They (certain yrs) have gotten a TSB extending the warranty on their tanks. Now we need to get our TJs included.
They may be replacing the tanks with similar ones that will eventually develop the same problem or there may be improved check valves. According to the Chrysler response to the NHTSA request, there is supposed to be a change in Feb, 2011. Don’t know how to verify that but if we can at least get the extension as the JKs did we can worry about the rest as it comes.
I’m reading some conflicting info about the TSB. It has been widely reported that Chrysler has replaced tanks for $100-150 & told these people that if there was a recall that they would be reimbursed. I read in another post that some guy was denied reimbursement on a replaced tank because it is not a recall but a “courtesy” warranty extension. This is new & I’m sure things will shake out for them. I’m not in a hurry to replace my tank but hope Chrysler gives the TJ owners the same consideration as the JKs. This problem started with TJs. Our Jeeps are older than theirs so it stands to reason that there are more of us with this problem.
Good news for some JK owners, bad news for the TJ owners:
NHTSA Action Number : PE10032 NHTSA Recall Campaign Number : N/A
Vehicle Make / Model: Model Year(s):
JEEP / WRANGLER 2007-2008
JEEP / WRANGLER 2-DR 4X4 2007-2008
JEEP / WRANGLER 2-DR 4X4 RHD 2007-2008
JEEP / WRANGLER 4-DR 4X2 2007-2008
JEEP / WRANGLER 4-DR 4X4 2007-2008
JEEP / WRANGLER SAHARA 2007
JEEP / WRANGLER X RHD 4X4 2007
Manufacturer : CHRYSLER GROUP LLC
FUEL SYSTEM, GASOLINE
FUEL SYSTEM, GASOLINE:STORAGE
FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY
FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY:FILLER PIPE AND CAP
FUEL SYSTEM, OTHER
FUEL SYSTEM, OTHER:STORAGE
FUEL SYSTEM, OTHER:STORAGE:TANK ASSEMBLY
FUEL SYSTEM, OTHER:STORAGE:TANK ASSEMBLY:FILLING/CHARGING
Date Investigation Opened : August 23, 2010
Date Investigation Closed : February 16, 2011
ODI found the rate of warranty claims related to fuel spit back on the subject vehicles is lower than other vehicles previously recalled to correct defects related to fuel spit back. Although the rate of complaints reported to the agency on the subject vehicles is higher than or similar to the rates experienced in previous investigations where safety recalls were conducted, ODI suspects that the NHTSA safety complaints submitted by subject vehicles owners may have been influenced by internet related publicity both before and during this investigation. A safety-related defect trend has not been identified at this time and further use of agency resources does not appear to be warranted. Accordingly, this investigation is closed. The closing of this investigation does not constitute a finding by NHTSA that no safety-related defect exists. The agency will monitor the issue and reserves the right to take future action if warranted by the circumstances. See attached report for additional information. In addition, Chrysler is initiating a lifetime warranty program, at no cost to the consumer, to address the fuel spit back problem in approximately 135,000 model year 2007-2008 Jeep Wrangler vehicles built from March 1, 2007 to March 31, 2008. Chrysler will notify all affected vehicle owners of this action. Consumers should refer to the warranty and service bulletins and sample owner notification letter available in the investigative file. The vehicle build date can be found on the certification label located on the driver door or door jamb.
Thanks, jkp. I see you have an '06 so you are in the same position as I am with my '05.
Classic good news/bad news. I think the TJ owners still need to complain to NHTSA. They think the net & these forums caused more complaints. OK how is that a bad thing? The problem still exists. Chrysler did a good thing. And a smart thing. By avoiding a recall, they don’t have to replace all the tanks, with an extended warranty they only replace the affected ones. Some tanks MAY never spit back & why should those be replaced? Still, the earlier TJs with the same problem (probably the exact same check valve) deserve the same consideration, don’t they?
I received warranty letter today also, but mine said it was for 2007-2008 Jeep Wranglers. The problem is the "inlet check valve". The warranty extension covers the "fuel spit back condition". The customer service number is 877-426-5337. I hope your jeep is covered, too.
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
This issue is not going away. Since 10-31-2011 (about 50 days) of the 19 new complaints for the ’06 TJs, 13 have been for fuel spitting out. For the ‘05s - 30 new & 26 for this. That is 39 new complaints in 50 days.
Yr model---date of 1st complaint--# of complaints (Fuel System Gasoline)
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!