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Topic Review (Newest First)
07-26-2014 06:00 PM
xrayguy 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.
07-26-2014 05:38 PM
RUBI 4 MY MRS 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 -

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

Problem with GM hose
Gas overflow fix hose problem with GM hose -
07-26-2014 04:43 PM
xrayguy 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?
07-26-2014 10:11 AM
yoopone 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!
03-24-2014 01:23 PM
lynn 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.
01-20-2014 12:33 PM
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.
01-20-2014 09:35 AM
DBoat mine is done too.. more more splashing out .. love it..
01-20-2014 01:06 AM
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
01-20-2014 12:44 AM
thetoadLJ 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?
01-19-2014 09:45 PM
lavern23 I did it too. I've filled up twice and this works great! Got mine from GM performance parts
01-18-2014 12:15 AM
Sinister6 I also did the GM filler tube. IT WORKS GREAT! Not a drop spilled
09-07-2013 11:37 AM
mvick36 Installed the GM part and filled up today. Works as advertised!
06-13-2013 08:09 PM
05wrangler Boy, mine looks nothing like that now lol
06-13-2013 07:55 PM
RUBI 4 MY MRS Here is the one I took off my '05 when I did the Hoppe mod GM hose.
06-13-2013 06:54 PM
05wrangler 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
05-19-2013 07:45 PM
SuperTJ Yeah I didn't care what the cause, just glad to find a fix. Works great.
05-19-2013 07:08 PM
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
05-19-2013 04:56 PM
SuperTJ Fixed it Friday and filled up Friday night. Worked like a champ.
05-13-2013 11:39 AM
SuperTJ Ordered mine today and hope to fix it over the weekend.
05-10-2013 06:34 PM
BeerChameleon 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
05-07-2013 11:33 PM
echobravo313 Yall just saved my fender flare, Gotta get on this soon as i can
03-31-2013 11:45 AM
horsedad58 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.
01-05-2013 11:19 AM
Originally Posted by 13Wrangler View Post
Has anyone simply removed the valve from the stock hose and put the hose back on?

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.
01-01-2013 11:15 AM
obiefox use your warranty
01-01-2013 09:29 AM
LAtkinsonVaRn I have a 2010 with this problem, what can I do?
11-09-2012 07:48 PM
13Wrangler Has anyone simply removed the valve from the stock hose and put the hose back on?

04-15-2012 10:04 AM
UnlimitedLJ04 very nice work!
04-15-2012 09:58 AM
Daddy_O 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.
04-14-2012 09:04 PM
LJMJ Filled up again, cost a million bucks, but NO spit back! Super coolio!
04-07-2012 08:02 PM
LJMJ 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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