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Topic Review (Newest First)
04-17-2011 04:57 PM
RUBI 4 MY MRS 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
12-29-2010 03:58 PM
cruisesinc Many 2006 model owners seem to have this overfill problem , as I did.

After several years , the valve built into the top of the fuel tank , sticks.

Only way to fix the valve is to replace the entire tank.

My 06 was still under warrantee so I got a new tank , but this should be a recall . Spilled fuel every fillup is dangerous.
11-08-2010 04:20 PM
1badasswrangler
Quote:
Originally Posted by 03 RUBI
The leak detection pump has nothing to do with it spitting out gas at the end of filling it up. The code for leak detection means that a leak has been found it what is supposed to be a closed system. You're overfilling it if gas is spilling out. Stop when the gas nozzle clicks off the first time.
It's not that on the gas spill. There is about a half of a second warning and then the gas just pours out. Mine does the same thing and I've tried everything. I finally just quit filling it up. Lol!!
11-08-2010 04:15 PM
1badasswrangler
Quote:
Originally Posted by Jellybird
So I've had my Jeep for coming up on a month. It is a 2006 Wrangler X 4.0 6 Speed. I'm in love with it. I've filled up completely 3 times in this month and each time as soon as it fills up completely some gas comes out. So with that being said, I have two questions.

1: Does anyone know why this is happening? (It has done it at 2 different gas stations)
2: How many gallons does my tank hold so I roughly know where to stop?

Thanks
Your tank holds 16 gallons and mine does the same thing.
11-08-2010 04:14 PM
1badasswrangler
Quote:
Originally Posted by cruisesinc
My 2006 Wrangler X 6 cyl developed this same fuel spill on fillup problem for the past year or so.
I just lived with it .

Then , my check engine light came on , code P0456.

Took it to the dealer as it was still under warrantee.

After they replaced the fuel cap,then the fuel lines, they discovered that valve on top of the fuel tank was sticking open .

They had to replace the fuel tank to replace that valve.
This fixed the check engine light problem .

However replacing the tank also fixed the fuel spill on fillup problem , hooray!
I have the same problem with the fuel spill. My engine light don't come on though.

I wonder how much a new tank would cost me?
11-08-2010 03:58 PM
cruisesinc My 2006 Wrangler X 6 cyl developed this same fuel spill on fillup problem for the past year or so.
I just lived with it .

Then , my check engine light came on , code P0456.

Took it to the dealer as it was still under warrantee.

After they replaced the fuel cap,then the fuel lines, they discovered that valve on top of the fuel tank was sticking open .

They had to replace the fuel tank to replace that valve.
This fixed the check engine light problem .

However replacing the tank also fixed the fuel spill on fillup problem , hooray!
02-22-2010 01:30 PM
s3nt3nc3d
Quote:
Originally Posted by HyperBuzzin View Post
Many of the nozzles here in PA don't have the lock-open latch. So, if it does over-fill, it's likely you'll get some gas on yourself.
That's what sparked us to start trying all the new tricks with our dumptruck at work... we were sick of having gas launched all over us and my parents were sick of me coming home and making the entire house smell like gasoline. Prolly a good thing none of us smoked...

...sure beats getting diesel all over your clothes though.
02-22-2010 01:25 PM
ps49556n
Quote:
Originally Posted by Jellybird View Post
So I've had my Jeep for coming up on a month. It is a 2006 Wrangler X 4.0 6 Speed. I'm in love with it. I've filled up completely 3 times in this month and each time as soon as it fills up completely some gas comes out. So with that being said, I have two questions.

1: Does anyone know why this is happening? (It has done it at 2 different gas stations)
2: How many gallons does my tank hold so I roughly know where to stop?

Thanks

I have the exact model, year, etc with the same issue. There are a few threads about this on jeepforum.com... While people will give you there own "opinions" of what they think is wrong, I have yet to find anyone who has concrete evidence of what part is causing the problem. What is known so far is that it is a problem related to something in the fuel tank. The problem is that the fuel tank is serviced as a complete part meaning that if one part within the tank is bad, correct procedure is to just replace the entire tank. This is fine and dandy but OUR problem is that Chrysler has not addressed the issue by recalling the defective tanks and releasing a new part. You can replace the tank but you WILL have this issue in a matter of time (months, years, it WILL happen again).

If your warranty is still active, chrysler will replace the tank for you if you call their customer corporate support number. You can call the same number even if your warranty is up and they will tell you to get the problem diagnosed at a dealership on YOUR dollar. If you do so and you get is successfully diagnosed, CHrysler usually will pay for half or more of the cost of the part and labor.


In my case, after spending $120 on a diagnostic that the dealership claims yielded no problems, I decided to live with it until chrysler recalls the part.....lol but do no hold your breath for that!!! GOOD LUCK!
02-22-2010 12:49 PM
HyperBuzzin
Quote:
Originally Posted by s3nt3nc3d View Post
I don't have this problem, but something you guys might try if you're not doing it already...

When you set the switch on the handle to keep the gas flowing, instead of setting it wide open...set it to the first notch.
Many of the nozzles here in PA don't have the lock-open latch. So, if it does over-fill, it's likely you'll get some gas on yourself.

I've tried all different ways to fill my GF's KJ. Nothing made a difference. Only way to be sure nothing splashes out is to listen for when it sounds like it's getting full or, by the gauge or mileage, know about how much can be filled and hope ya don't guess too much.
02-22-2010 12:38 PM
s3nt3nc3d I don't have this problem, but something you guys might try if you're not doing it already...

When you set the switch on the handle to keep the gas flowing, instead of setting it wide open...set it to the first notch. Sometimes it'll allow it to click off before it sprays gas back out...or at the very least, it may reduce the amount of gas that sprays out.

We have a dump truck at work that has problems with both fuel fillers...if you don't hold the handle right, it'll build up pressure and shoot gas back out the filler neck. If you pump too fast, it'll do the same thing...or it'll shoot a good half gallon out once it's full.

In order to even get gas in the tanks, we have to put the nozzle in upside down and then set it to the first notch on the handle to keep a slow, steady flow. It still overflows a little bit...but nowhere near as bad as if you tried filling it normally.

Just an idea...
02-22-2010 11:40 AM
Lionheart I'm a new Wrangler owner so I don't have a lot of experience (only two fillups, that new) filling up. The first time I just shoved the nozzel in and let 'er go, I got the back splash, the second time I push the nozzel all the way in then backed it up just a little and didn't get the backsplash.
02-22-2010 10:58 AM
HyperBuzzin
Quote:
Originally Posted by 03 RUBI View Post
You're overfilling it if gas is spilling out. Stop when the gas nozzle clicks off the first time.
Ummm, that's the problem, as stated in the first post.... a LOT of Jeep's (like the OP's) don't click off AT ALL!!
Yes, it's over-filling, but only because something isn't letting back pressure build up to shut off the fuel nozzle. Not because people are intentionally going past the nozzle shut-off point.
02-21-2010 10:57 PM
03 RUBI The leak detection pump has nothing to do with it spitting out gas at the end of filling it up. The code for leak detection means that a leak has been found it what is supposed to be a closed system. You're overfilling it if gas is spilling out. Stop when the gas nozzle clicks off the first time.
02-21-2010 10:48 PM
blinx Its probably the leak detection pump, like 50 or 60$ and it will fix you up. When they go that happens. Bad part is it always isn't bad enough to kick the code for it.
02-21-2010 10:37 PM
03 RUBI My spec sheet says 19 gallons.
02-21-2010 10:16 PM
SPDNJOE Here you go, read this

Have FUEL spill problems like MANY of us? Submit a complaint to force a recall!!! - JeepForum.com
02-21-2010 10:01 PM
Jellybird Thanks, a lot. I wasn't sure if it was mine that was just messed up or if it was an unfortunate occurrence for others.
02-21-2010 09:40 PM
HyperBuzzin It's not just TJ's that this happens to. My TJ Unlimited doesn't do it, but my girlfriends KJ does.
Just like vibes when installing a lift, some Jeeps do it, some don't.
02-21-2010 09:39 PM
debruins from E mine takes about 16 gal. and it will gurgle and then you know you're full
02-21-2010 09:26 PM
JDsDream Apparently it is a flaw that most TJs have. The only thing that works for me is after putting the nozzle in your filler, twist the handle a little to the left. I noticed that when I fill the tank, if I hear a gurgling sound (for lack of a better word) while filling, it will more then likely spray gas when it is full. There are 2 stations in my area that are consistently that way. The station that I usually use does not. As far as your tanks capacity, my 2006 manual says that it holds 14 gallons, but it actually holds 19. Hope this helps
02-21-2010 09:15 PM
Jellybird
Filling Up and Coming out?

So I've had my Jeep for coming up on a month. It is a 2006 Wrangler X 4.0 6 Speed. I'm in love with it. I've filled up completely 3 times in this month and each time as soon as it fills up completely some gas comes out. So with that being said, I have two questions.

1: Does anyone know why this is happening? (It has done it at 2 different gas stations)
2: How many gallons does my tank hold so I roughly know where to stop?

Thanks

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