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2005-2006 TJ LJ - Fix for gas overflow issue

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76K views 70 replies 42 participants last post by  Digger84  
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#1 ·
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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#5 · (Edited by Moderator)
SHoppe715 said:
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.
Click to expand...
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.
 
#17 ·
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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#28 ·
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.
 
#29 ·
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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#31 ·
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 :whistling:

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! :nonono:

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