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SoccerJeni 02-01-2011 11:04 AM

Gasoline overflow
I have had my 2006 Wrangler for about a year. I cannot fill up my gas tank to the top because gas always spills out. I was wondering if anyone else has had this problem and if this is common?

Does anyone know what's wrong?

PTaylor 02-01-2011 11:08 AM

I think it is, or I've seen others make the same complaint about refueling.

wnesbit13 02-01-2011 11:13 AM

I have a 2008 Sahara and you can't add any after its full.

SoccerJeni 02-01-2011 12:02 PM

Well, I actually have to stop the gas pump from filling up until it clicks. I am never able to fill it up. I have to guess when it's about full and stop the pump. So, I never ever do that top it off thing.

Has anyone had this issue and had it fixed?

OKLAHOMA_TJ 02-01-2011 12:05 PM

My Chrysler Aspen does this.

2 options... Auto fill on a slower setting. Or try a different gas station until I find one that works..

SoccerJeni 02-01-2011 12:07 PM

Okay, thank you!

There has only been 1 time that it did not overflow in the last year, and I went to that gas pump again and it did overflow. I will try the slower setting when I'm nearing the end. This is just annoying. Sometimes you want to wash your windows and not worry about it.

Wrangler06 02-01-2011 12:08 PM

its not the pump or station its somthing to do with the gas sensor in the aunt has an 06 as do it..hers happened all the time while mine NEVER did until about 2 weeks ago when i read another thread about it now it does it everytime lol you cant put the pump all the way in the gas have to let it hang out a little bit ..its gotta be just right for it not to over fill and since ive been thinking about it i cant get it right lol atleast this helped for me

SoccerJeni 02-01-2011 12:18 PM

Lol...well, that is a bummer Wrangler06. Thanks, I'll give that a shot!

SnowBlast 02-01-2011 10:02 PM

Just got an 05 Rubicon and first time I filled the tank I put on the latch to put my hands in my pocket and it overflowed! Thought it was the angle jeep was on or something. Filled it up next time and no issue. Something I will be keeping any eye on. Looks like its just another Jeep "Feature"...

NighthawkIII 02-01-2011 10:27 PM

I just bought an 03 Wrangler and when I went to fill it up the first time, just before the pump kicked off I could hear the gas splash under the Jeep. I checked for loose lines and I found that the ring that holds the fuel pump in place was just laying there on top of the tank. I had to pull the tank and put it back on. While I had it apart I went ahead and changed the fuel pump seal. So far so good with no more leaks. There is also a rollover valve and line to it and another larger line that is for the emissions system that goes into the tank. One of them could be off or broken. The only other thing I can think of is the overfill line that runs with the filler neck could be off the tank end of the line. This is easy to check if you have a multi tip screwdriver with torx bits. Just remove the 4 screws around the filler neck and the 4 screws that holds it to the body. Remove the piece and look down the hole. You can see where the filler hose and overflow hoses connect to the tank to see if they are on and tight. Hope this helps.

4 Jeep Family 02-02-2011 03:57 PM

My Dealer gave me a price to replace the tank of $384.00 total.
I called Chrysler at 1-800-992-1997 talked to complaint department. They will review it and get back with me on Thursday Feb. 3 2011. They said they might replace free it as a Good Will on their part.

Jeepchic70 02-02-2011 04:04 PM

I have two TJ's and they both do it. The '05 is worse than the '98 though. At least the older model I can hang it out a bit and it stops. The '05 never gets full because no matter what I do, it overflows. Annoying! Lots of threads on the same subject on the forum and everybody's does it or at least a lot of them do.

97sport09 02-02-2011 04:21 PM

Mine will stop, say at $45.03, and I want to put $45.50, I can never do it, will flow over before I get there lol

TexasT 02-02-2011 06:13 PM

My 99 started doing it a few years ago but I thought it was because of a rock/gas tank incident.

97sport09...the way gas is going up that extra 50 cents will only come out to a bottle cap of gas and you should be able to get closer. Make you feel better? 

Kilcrease 02-02-2011 08:03 PM

My 06 does the same since I've owned it for a year. Like they said just put in slow it in slower and will cut off before spewing out. I asked the dealer and they had no idea what could cause it it's just something about the TJs

OKLAHOMA_TJ 02-03-2011 02:38 AM

"put it in slower"

That's what she said:)

gosnell 02-03-2011 02:46 AM

She told me faster!!

Victor Ward 02-03-2011 09:51 AM

From what Ive seen on here its a common problem. When I first got mine I spilled gas every where a coulpe times.

Now I only put the gas nozzle in as little as possible so it can sit there on its own with out me holding it. that way it fills and clicks its self off with out the spill.

4 Jeep Family 02-03-2011 12:10 PM

Chrysler called today, Chrysler will put in a new tank for $125.00. My Jeep has 40,000 miles 2008 Rubicon. Chrysler has to confirm with the dealer that you need a new tank.

RUBI 4 MY MRS 02-15-2011 08:02 PM

Gas spills out
Iím new to this forum so I hope this helps & has not been discussed previously.
I have had a '05 Rubi from California since 4-09. It started spitting gas several months ago. At first I thought it was the nozzles at the station I generally use. I recently filled up in Las Vegas where they have the fitting on the nozzles to prevent spills & vapor release. Even there it spit gas out. My local dealer said itís not uncommon for this problem & depending on whether itís "in the neck" or needs a "new tank" it would be either $300 or $700. I decided to do some research on my own. According to the factory service manual there is a valve in the tank that opens a large vent to the charcoal canister to capture fumes (vapors) during fueling. When the tank is full, the valve closes. With a closed vent the only place for the displaced air in the tank to go is out the filler causing, I presume, gas to spill out. To prevent this there is a check valve just inside the filler neck in the tank. It is supposed to close when there is pressure against it as a result of the vapor vent closing. When this check valve closes gas fills the filler neck & causes the gas pump nozzle to shut off. (no pressure, no spitting) Well that is the way it is supposed to work. Obviously there is a problem somewhere. Iím assuming itís the check valve & it is stuck in the open position. If the vapor valve malfunctioned, I think that with no venting the tank would fill slowly from the start. I took the filler neck & tube off from the tank inlet. I could see the check valve. There didnít seem to be a way to tell if it was stuck. Iím going to fill the tank & try again. Iím not sure if having gas up to the back of the check valve will cause it to close or if it only closes under pressure. I think itís worth a try. I see tanks for from $300 to $600 so if itís the check valve & it can be freed up it would be a good way to stop the annoying habit these Jeeps seem to have.

jkp 02-15-2011 09:55 PM

There is a NHTSA investigation into this:

Affects late model TJs, JKs and other Chrysler products.

RUBI 4 MY MRS 02-15-2011 11:04 PM

JKP, Good to know. I notice they mention the check valve. It appears that the valve is "bonded" to the tank & not removable. Too bad because it would be an easy repair if it was.

Sweat it 02-15-2011 11:15 PM

My 06 does the same. I just slow it down when it get close to full! But if someone finds a fix I'd like to know.

SilverTJMike 02-16-2011 12:48 AM

Been covered real well over here Gas spilling over when filling -

That said its a check valve in the tank that swells and no longer moves. Source is apparently ethanol in the gasoline.

Chryslers response to the complaint.

You bring your jeep in and get it diagnosed.
Call the number in the previous link (1-800-992-1997) and get a case open with chrysler. I think you can do it on there website as well.
Open a case with NHTSA as well.
You WILL need your VIN.

Chrysler will call you, you explain the issue, they call the dealer, they talk, copay and you have a new gas tank installed. Pain in the butt!

I just went through this for my 05 TJ , gas used to dump and spray all over depending on the wind. Works fine now :) Of course they haven't redesigned the tank yet so it will happen again :(

RUBI 4 MY MRS 02-18-2011 05:26 PM


Thanks for the info. I read all 32 pages in that thread. Lots of good info. I also read the response to the NHTSA. Chrysler claims that an improved valve will be available in Feb 2011 (now?). I wonder if they will change the tank part # & remove the old inventory so we will know if we are getting the improved design if we go for a tank replacement.

Again, thanks,

SoccerJeni 02-19-2011 03:04 PM

Wow! Thanks for all this information guys! So, SilverTJMike, did you have to pay anything to have your gas tank replaced?

I figured there had to be some kind of a recall on something that needed to be done by Chrysler! I think I'll call that number you supplied SilverTJMike. Thank you!

SilverTJMike 02-20-2011 10:54 AM

I am not sure if I received a new tank or not but the cost for tanks went form about 250 to ~600 at

I paid 97 for diagnoses and another copay of 103 so 200 total so my gas tank doesn't overflow.

4 Jeep Family 02-22-2011 09:51 AM

Here is what the dealer should look up. TSB 14-001-11

RUBI 4 MY MRS 02-22-2011 06:18 PM

4 Jeep Family,
That is great info but do you have a TSB for the TJs? There are a lot of TJs with this problem but Chrysler seems focused on the YJ. From reading their response to the NHTSA request, posted above by SilverTJMike, they are using warranty records. Most of our (TJ owners) problems started after warranty. I think this should fall under the emissions waranty of 5 yrs. My '05 started having this problem before 5 yrs but like most of us thought it was a gas nozzle problem. Now at 6 yrs, I figure it out.

Anyway if there is a TSB for the TJs & anyone has it please post it.

jkp 02-22-2011 07:50 PM

No, they are blaming the TJ owners:

And currently they are just replacing the defective design tanks with another one of the same design. The problem will return.

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