The hose is not a fix it's a band-aid. The fix is to drop the tank and sand down the "nubs" on the plunger in the valve.
Wrangler TJ Gas Overflow Fix
- Thread starter Chris
- Start date
The hose is not a fix it's a band-aid. The fix is to drop the tank and sand down the "nubs" on the plunger in the valve.
This.
It's not a hard repair. Getting the tank out is the hardest part. And, it's not hard.
Do it right and never worry about it again.
Did this yesterday, the little knobs/ridges didn't need much sanding. I would recommend doing a little at a time with a piece of 220 grit and checking back and forth. Word of advice, make note of which way the fuel pump is clocked. I ended up breaking the line connection off the top of the fuel pump trying to get it to fit. However, the need fuel pump made a world of difference, throttle delivery is much smoother and a miss I had was gone. Took me about 3 hours by myself with almost having the tank reinstalled, dropping it again and installing the new fuel pump.
It's a great repair for anyone dealing with this problem. Jeep should have done a recall to fix it back in the day. I was refilling every 2 days due to commute and overflowed everytime.
This is such an easy fix. I took years to get to it......
FOR ANY FUTURE READER:
It's a grab and apply soft but strong pressure within the tank to get off the fixture the plunger is within. It's blind and intimidating but go for it - you'll get it off. That's the hardest part of this effort to fix an issue that will damage your paint, flares, etc.
This is such an easy fix. I took years to get to it......
FOR ANY FUTURE READER:
It's a grab and apply soft but strong pressure within the tank to get off the fixture the plunger is within. It's blind and intimidating but go for it - you'll get it off. That's the hardest part of this effort to fix an issue that will damage your paint, flares, etc.
You are so right about that.
I was terrified that I was going to break something. Blaine encouraged me, and sure enough, it came right off.
Took me about 3 tries to muster the courage that I wasn't going to break it.
Is there a recommended brand for the fuel pump? Mopar OEM only or are there any others that work?
Hey all, I did the GM hose fix a few years ago, and now having the same issue with this one. Has anyone encountered another more permanent fix for this, and also perhaps a temporary when you’re in a pinch and just need to fill up until you can get around to another replacement?
Cheers.
Cheers.
Yes. The permanent fix is to drop the tank and do the fix correctly. It's not hard just a little time consuming. Earlier in the thread covers the details.
Chris should put the real fix in the first post.
deadbeat son
TJ Addict
Thanks for the words of encouragement on this part! I was afraid I was going to break it until I read these posts and yanked at an angle with gusto. The hardest part of the fix was either pulling the overflow valve housing out, or getting the metal fuel pump lock ring back on. An appropriate sized BFH took care of the latter.
This fix was so worth it. It was amazing to fill up with the pump at full speed, zero cut offs during fill up, and correct shutoff when full. Hard to believe something like that makes such a satisfying difference, but it really does.
Knock on wood, I’ve been knocking my knuckles a few times on the tank near the fill hose before fill up and seems to loosen things up to fill without issues lately. Mentioning especially for anyone that might otherwise get stranded without being able to fill, and/or for those that want to give it a shot to postpone a repair (not that I’m suggested you do what I’m currently doing). Curious if this works for anyone else successfully too… Hope this helps someone get out of a bind.
Read the first post again. The GM hose is not the fix. There is nothing you need to purchase.
I assume you have a 2005-2006? Drop the tank and fix it right. I had the gas spit back in my 2005. Dropped the tank, did the fix, zero problems filling now.
If you don’t know when/if your fuel pump was last replaced, it’s a good time to do that now since you have to remove the fuel pump to get to the check valve.
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