Fuel/Gas overflows at Pump EVERY Time!

Tekavec · **Posted:** Thu Sep 29, 2011 7:18 pm

I have a 2005 3.7L KJ.(70800 miles) Every time we fill up at any gas station the fuel overflows. I would like to know how many of you have this same problem.

I opened a Complaint with Jeep and they blew me off. The dealer say a new tank must be installed a a significant cost.

Are there other solutions?

Thanks,
Scott

tjkj2002 · **Posted:** Thu Sep 29, 2011 7:22 pm

Yep a new gas tank needs to be installed and they are pricey.Your well past any warranty coverage so yes your responsible for paying to have it fixed.There is a TSB for it but unless your in the 3/36 warranty you pay out of pocket.

TheBartlett · **Posted:** Thu Sep 29, 2011 7:30 pm

I had seen in a post about this same problem a suggestion to turn the nozzle 90° when pumping to prevent the overspillage. I have tried it and can say it does help, but only works half of the time. I just know that when the low fuel light comes on, I can safely put in about 16 gallons without spilling, and the fuel gauge reads full. I know I'm not taking on as much fuel as I could, but I'm not spilling gas down the side of the jeep either.

TheBartlett

67Customs · **Posted:** Thu Sep 29, 2011 10:30 pm

Mine does the same thing. My solution is simple. When the tank is nearing full, I barely squeeze the pump. It fills it up and shuts it off with not overflow.

dieselenthusiast · **Posted:** Thu Sep 29, 2011 10:37 pm

67Customs wrote:

Mine does the same thing. My solution is simple. When the tank is nearing full, I barely squeeze the pump. It fills it up and shuts it off with not overflow.

X2, you can hear it when it’s close to full.

infernicus · **Posted:** Thu Sep 29, 2011 11:52 pm

Since I'm the only one driving my truck, I usually fill up at half a tank.

Since I have a 20.5 gallon tank I usually pay for ~11 gallons, just enough to get to full, but not enough to overflow.

At least for me, there's no need to fill it to capacity. With that being said, I once put like 21.999999999999 gallons in it.
Which means my fuel pump was not happy, but, I had to see how far I could drive!!

"I’ve been in the slash many times. This is nothing. You’ll get used to it." Oh Kramer.

BugginKJ · **Joined:** Mon Jul 06, 2009 7:35 pm **Posts:** 4576

My 07 doesn't have that issue other than at one station but that place fills at nascar speeds. My neighbors does how ever and theirs is an 03, I think, he tells me he has to pull it out slightly and fill on slow to avoid the over fill spillage.

Se7enLC · **Posted:** Fri Sep 30, 2011 11:46 am

Mine does that EVERY. SINGLE. TIME. It shuts off just AFTER spraying fuel all over the place.

I assumed at first that it was the pump that was responsible for automatically shutting off, but after I noticed it happening at multiple places I looked into it further. Apparently there's something in the tank that does it. It's an annoyance, but not worth the cost of the replacement tank. I'm guessing design flaw that not enough people complained about to get Jeep to fix it.

I wait until my low-fuel indicator comes on, fill until it says about 16 gallons, then let out the handle and fill the rest of the way very slowly. The auto shutoff does still work, it just only works when you fill slowly.

The real problem is that I live in a nanny-town that doesn't allow self-serve gas, so I have to explain to every attendant that it's going to spray fuel out if they don't pay attention to it.

67Customs · **Posted:** Fri Sep 30, 2011 11:49 am

infernicus wrote:

"I’ve been in the slash many times. This is nothing. You’ll get used to it." Oh Kramer.

Haha. That was a great episode. Heck, every episode of that show was great.

Se7enLC wrote:

I'm guessing design flaw that not enough people complained about to get Jeep to fix it.

It is a design flaw and it doesn't only affect the KJ's. My dad's '09 JK also had the poblem, but he got his take and filler neck replaced under the 3/36 warranty. Mine was out of warranty when the problem started happening, so yeah, not worth me replacing.

mikey1273 · **Posted:** Sun Oct 02, 2011 7:51 pm

That is something I have never had that with mine so there must be something very different about the gas and crd versions. I think the tanks are the same size and all crd would not have vapor recovery

bunkermonkeycw · **Posted:** Sun Oct 02, 2011 9:24 pm

I was there and then a tow truck ripped a hole in my gas tank... new gas tank did solve it ((LOL)ish), sure got muddy and stuck that night... 15 miles from anywhere... with no reception... hiked out to a resort, called a tow truck cuz all my jerk friends were out or busy, tow truck got stuck (booty was out in a field with RWD wrecker, how would I know) we ended up cutting a down tree with a hatchet to get far enough back to get speed and hit the last pit and hill out...that was a 2pm to 9am ordeal.... :JEEPIN:

Sorry off topic but... I had to.

Tekavec · **Posted:** Mon Oct 03, 2011 7:05 pm

Glad to hear that I was not the only on with this issue. Looks like I can buy a tank on-line for around $300.

Probably will put it in myself. This is my wife's primary vehicle hate her getting gas on her shoes!

liquidxit2 · **Posted:** Mon Oct 03, 2011 7:29 pm

I also hear the new tank and stem dont 100% fix the issue.

bunkermonkeycw · **Posted:** Mon Oct 03, 2011 9:31 pm

liquidxit2 wrote:

I also hear the new tank and stem dont 100% fix the issue.

Its a venting issue for sure, too little pressure for the pump to know its full? or....

"first, make sure the fuel filler hose is not kinked or plugged, next check the valve for releasing the vapor on the gas tank, if that is good check all vaccum lines and the charcoal canister" -google

"Many have had this problem and some say just to not put the nozzle in as deep, like maybe 3 inches down and try that. The bottom of the fuel nozzle generally has a bend in it, try to keep it a bit straighter, so the bend is away from the wall, will help." -google

My favorite so far.

"Mine did the same thing, I used the lowest pump flow I could as the tank filled up. Sometimes it would still do it. I'd say the gas filler neck does not allow air to be expelled quick enough, and when it "burps" it shoots the gas back out. Sort of like a human after 15 or 16 beers. -google" :5SHOTS:

liquidxit2 · **Posted:** Tue Oct 04, 2011 8:42 am

I always guess how many gallons i need then use this simple procedure:

Say i need ~17 gallons Ill fill at the fastest rate until 15 gallons then ill let the system burp for a second and then fill at the slowest rate the pump will go.

Has worked since the tank started over flowing every time and only adds a minimal ammount of time to fill ups. I also havent had an overflow in a loooong time, but i cant say this is the cure for all.

If i fill at anything over the lowest rate i get massive fuel spillage.

hooperswish · **Posted:** Tue Oct 04, 2011 9:23 am

dieselenthusiast wrote:

67Customs wrote:

Mine does the same thing. My solution is simple. When the tank is nearing full, I barely squeeze the pump. It fills it up and shuts it off with not overflow.

X2, you can hear it when it’s close to full.

X3, plus, they say you can get a little better gas mileage by filling up slowly, as the fumes mix in and make the fuel more combustable, or something to that effect.(sounds unlikely, but I did hear that on drive radio here in Denver, and they know their stuff. But who knows for sure) Just fill up when you have a couple of extra minutes...

MonsieurGlen · **Posted:** Tue Oct 04, 2011 4:09 pm

BugginKJ wrote:

My 07 doesn't have that issue other than at one station but that place fills at nascar speeds. My neighbors does how ever and theirs is an 03, I think, he tells me he has to pull it out slightly and fill on slow to avoid the over fill spillage.

Mine is the same way. I only get the spillage at 1 or 2 stations, and I have filled from a half tank all the way to 20.9 gallons down (I went about 40 miles after the EVIC said 0 miles to empty).

XJMA · **Posted:** Wed Oct 05, 2011 11:49 pm

We have three KJs here at work that we can all drive, two 06s and one 07 and all three of them have done it since day 1. My wife's 04 has never had an issue!!

I knew it was common but didn't know that it would/could be covered under the warranty!?!?!!!!! WTF!! They were like that since day 1, we thought that it was just something that we had to deal with!!!

Oh well, the way we deal is that basically 1/4 tank is ~5 gallons so we just fill accordingly and slow it down at the end. Still get surprised every now and then though. It's especially tough on the 07 that I always drive because the fuel gauge doesn't work so I have to go off of miles traveled!!

Fuel/Gas overflows at Pump EVERY Time!

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