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Thread: IMPORTANT: Gas Spillage 03+ TJ/LJ

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    Still Growing Too! Big Green's Avatar
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    Exclamation IMPORTANT: Gas Spillage 03+ TJ/LJ

    PLEASE cross post as necessary and required!

    Last summer I purchased my new to me LJ and starting with the first time I filled up if overflows. After some recent research I have discovered this is a very common problem with these Jeeps. Chrysler HQ almost refuses to acknowledge the problem and will not, or at least for now, has not presented a mass solution.

    Here is the best explanation of what is happening, quoted from JF.
    Quote Originally Posted by Maxxram View Post
    I dropped the tank today to install my new Savvy Skid and pulled the fuel pump to find out what is going on the the check valve on the filler tube.
    What I found was that our tanks don't use a simple ball like on older tanks, instead they use a plunger of sorts that has a spring below it. This spring is very very weak. I reached in the tank and could freely move the valve up and down. Also the end of the valve had a triangular shaped tail on it that slides in a cutout in the bottom of the filler tube. What happens is that the valve guide gets stuck when it gets pushed all the way down. (When gas flows into the tank) This is why when filling it shoots fuel back out because that valve sticks. I tried getting pics of the inside of the tank but could not get them to come out right.
    The people using the pour in cleaners are having limited luck because when you pour it in it lubricates the guide that the check valve slides in for a short while.
    Also I believe that if those of you who got the tank replaced, if they are the same design it is just a matter of time before it starts to fail again.
    If you are having this problem also, please call Chrysler at 1-800-992-1997 and register your complaint with them. Also, make sure you go to Office of Defects Investigation (ODI) and register your complaint with them also. Even if you have "fixed" the problem already doing the work yourself or have learned to cope with the problem, let Chrysler and the NHTSA know about the problem. Jeep needs to get this fixed.

  2. #2
    9mm is faster than 911 Shortcut's Avatar
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    Quote Originally Posted by Big Green View Post
    PLEASE cross post as necessary and required!

    Last summer I purchased my new to me LJ and starting with the first time I filled up if overflows. After some recent research I have discovered this is a very common problem with these Jeeps. Chrysler HQ almost refuses to acknowledge the problem and will not, or at least for now, has not presented a mass solution.

    Here is the best explanation of what is happening, quoted from JF.


    If you are having this problem also, please call Chrysler at 1-800-992-1997 and register your complaint with them. Also, make sure you go to Office of Defects Investigation (ODI) and register your complaint with them also. Even if you have "fixed" the problem already doing the work yourself or have learned to cope with the problem, let Chrysler and the NHTSA know about the problem. Jeep needs to get this fixed.
    Thanks for the Great Problem Report/heads up,

    That would explain why TJ&LJ filler necks are on backorder nationally.

    Bob
    To become an AMSOIL Preferred Customer and save 20 - 25% off of the retail prices click on the following link

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    800-750-0000

  3. #3
    Still Growing Too! Big Green's Avatar
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    Quote Originally Posted by Shortcut View Post
    Thanks for the Great Problem Report/heads up,

    That would explain why TJ&LJ filler necks are on backorder nationally.

    Bob
    Not a problem.

    The filler necks have nothing to do with the problem though. Don't know why they would be backordered. Perhaps people are just trying one thing at a time to fix it and they are starting there.

    Here is the original thread on JF. Through trial and error they have ruled out everything and a few dealerships know what the problem is already having fixed so many. Problem with that is they are replacing the tank and the replacement tank has the same faulty design.

    Gas Spilling Over When Filling
    Last edited by Big Green; 02-14-2010 at 17:27.

  4. #4
    Back to 1 Jeep... for now rroadkilll's Avatar
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    And I thought that the problem with mine was because I made the 15 gallon tank into a 19 gallon (or there about) tank!!!

    Good information... I'll check it when I take it down!

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    Free at last... ColoFreeJeeper's Avatar
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    Yeah mine does this too.

  6. #6
    Snow Jeeper treefrog's Avatar
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    Hmmm. Never heard of this and I've had my TJ for a little better than 6 years now. Mine is an 04 Rubicon. Is this a model specific problem, or a hit and miss problem? Just curious.
    treefrog

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    Junior Member Albeham's Avatar
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    same here , mine is a 04.5 LJ, never had that happen..yet.. tell us more..

    You can follow me..but it is gone to hurt.

  8. #8
    Still Growing Too! Big Green's Avatar
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    Quote Originally Posted by treefrog View Post
    Hmmm. Never heard of this and I've had my TJ for a little better than 6 years now. Mine is an 04 Rubicon. Is this a model specific problem, or a hit and miss problem? Just curious.
    03+ for sure. I believe there was a design change that year with the fuel tanks that incorporate the faulty design. Re-read the part in read in the first post for a better description of the problem.

    Quote Originally Posted by Albeham View Post
    tell us more..
    The first post and then the link I posted to JeepForum explains in great detail.

    This is the same thing mine does everytime too. I even try to listen to when it sounds like it is getting fuel, but by then it is too late as it gushes out all over my LJ. I haven't found a solution for mine yet, not holding it a certain way or even going really slow. My only solution is to either not fill up or just go wash it after I do fill up.

    http://www.youtube.com/watch?v=FxFgU_7ulY8

  9. #9
    Junior Member Carl's Avatar
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    I have a 06 LJ that does that also. Thanks, I will register my complaint.
    2012 Jeep JK Sport, 3" Zone Suspension Lift, 305-70-R17 Nitto Terra Grappler AT tires, 17x9 Ballistic Wheels

  10. #10
    G.I. Grandpa SGM O's Avatar
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    Not had this problem with my '06 Unlimited, but I will let my wife know.
    As for back orders, that happens when companies don't pay their bills...Chrysler makes nothing, all they do is assemble vehicles, and there are alot of parts on back order.

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