Wrangler TJ Gas Overflow Fix

Chris

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The Real Fix

The issue of gas "burping" out of the filler neck right after the pump clicks off when the tank is full is a fairly common issue among Jeep Wrangler TJs. The cause of this is the ethanol in the gas causing plastic parts in the Inlet Check Valve (ICV) to bind and not close quickly enough to prevent fuel back-splash when full.

Owners of 2005 - 2006 TJ Wranglers were left up shit creek by Chrysler and the NHTSA on this one. '07 and newer got a warranty extension (NHTSA closed the investigation taking the heat off Chrysler) '05-'06 owners got the shaft. There's almost no point I filing a complaint with NHTSA any more because our complaints were already dismissed as "Internet hype".

Using the GM hose to address the "fuel spit back" problem is a hack (see below for the "hack" fix). This technique was first posted in the Internet many years ago and has made the rounds enough times in the jeep forums that it has become permanently embedded in the collective knowledge base and won't go away.

The problem is caused by a sticking plastic overflow valve at the inlet to the fuel tank.

The actual fix is is to drop the tank, sand the nubs on the plastic piece in the overflow valve , reassemble the valve then raise the tank back in place. The only "part" required is a piece of sandpaper as shown in the video below.




The Temporary Fix

This is the original "fix" for the fuel spit back problem. While it will usually fix the problem, it is a band-aid at best, and should only be thought of as a temporary fix, whereas the above method is the actual long term fix.

This is how GM fixed the exact same problem in the Trailblazers, Envoys, Bravadas, etc.

Amazon has the replacement part for around $30 here:
http://www.amazon.com/gp/product/B00GUCRISO/?tag=wranglerorg-20

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The bulge in the middle is a little flapper valve:

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Here's our lower hose that connects the filler tube to the tank:

4_filler_fix.jpg




Here's a how to guide:
The inside diameters are identical. Cut 1 1/4"off the small end and 1 3/4" off the big end. I started out only cutting about 3/4" from the small end to make it the same length as our hose, but it can't make the bend without kinking. I cut some more off and it made for less of a bend and no kink. If you have a body lift, you'll probably need to cut less off. Start small, you can always cut more but once you cut it too short you're on your own...:

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Swap your old clamps onto the GM part:

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The lower clamp has a little clip on it that you put at the top of the hose so you can feel that it's oriented right when you put in on the tank. The round notch on the GM hoseis there to align it with its intended tank, use it as a reference for installing the Jeep clamp. This is very important when it comes to re-installing the new hose. You'll have to feel for this clip because you won't be able to see it clearly:

8_filler_fix.jpg


That's it!

Reinstall and you're done. I had to remove the 4 torx screws attaching the filler neck to the body to get the new hose on it. I didn't have to disconnect any other lines or take it completely out, but just needed to move the neck around to get the new hose on.


Removal and istallation on a TJ is extremely simple.

Access through lower wheel well cover:

9_filler_fix.jpg


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Loosen the 2 hose clampsand remove the original rubber hose. (1/4" screw clamp upper & 5/16" screw clamp lower) I found it easier to remove the stock hose with the upper filler neck still attached to the body so I could pull down on it.

Cut GM hoseand swap Jeep clamps over (see previous posts).

Remove the 4 torxscrews attaching upper filler pipe to body. You don't have to remove the pipe completely. I didn't even disconnect the tank vent, axle vent, and locker pump lines. You'll only need to move and twist it around a bit to get the new hose on:

11_filler_fix.jpg


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Install modified GM hose, tighten all fasteners, replace trim pieces as necessary - you're done!!!

Note: Make sure the hose is oriented correctly. If the flapper sits crooked or upside down it won't work right. The round notch on the big end of the GM hose before cutting it is for orienting it to its intended tank. You'll have to feel for the little clip on the Jeep hose clamp and make sure it sits at 12 o'clock on the tank inlet.

Here's the installed hose:

13_filler_fix.jpg
 
The above was originally posted by SHoppe715 on JeepForum.com 02-27-2012. It’s been linked to in a number of places. It was one of the first fixes I made to my 2005 Wrangler when I bought it in June 2015. It is straight forward and works great - exactly as described.

The part is GM Fuel Tank Filler Hose #15131046. It's available on Amazon new for <$30, so don't mess with finding a used one.

A few additional things to note: The wheel well liner is held on by a number of plastic plugs you can remove (carefully) with a door panel remover tool (looks like a screwdriver pry-bar with a slot in the blade). I was able to save and re-use all of mine. Access to the old filler hose clamps is limited. I used a mini right-angle ratchetting screwdriver to undo the old hose clamps. Once I got the original fill hose out (with a little rocking, tugging, prying, and cursing), I used an electric miter saw to cut the new hose to size. It gives a nice clean cut on these heavy reinforced hoses. I made several passes, going back and forth to the jeep till the length was just right since you can’t un-cut. That said, his measurements were accurate. The new one goes on much more easily. If it's cold, you can blow the ends of the new hose with a hair dryer or heat gun a bit to soften it up. (Obviously, don't try to loosen the old hose this way, as it is connected to a gas tank, gasoline vapors are EXTREMELY FLAMMABLE and you would risk an explosion ;-) I put on new stainless hose clamps, rather than use the old partially corroded ones and was able to tighten them with a normal nut driver. Reassembly was easier than disassembly.

Good luck.

BTW - Another issue with 2005 and 2006 Jeep Wranglers is a wiring problem with the OBD-II computer which results in it not resetting properly. This will result in your failing a vehicle emissions test, if your state has them. Chrysler put out "TSB 25-001-07" for this problem. It's a lifetime warranty repair. Any Jeep dealer will fix for free if you encounter it.
 
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My 1997 TJ has an issue at the gas station.... while filling up, the gas pump will "click off" way too soon... and I end up with only about 3/4 of a tank of gas.... After the gas dispensing nozzle clicks off I can sometimes just "barley" squeeze the handle and allow a slow trickle of gas into my tank, it takes a while but I can finally get a full tank of gas.. I'm wondering if the MOD described in this link would address my issue.
 
My only issue filling up is only being about to get 15 gallons in my tank when it's completely empty. It's been like this since my last trip to big bear and my gas tank/skid took a BIG dent to the passenger side on the rocks. If I park with my drivers tire up in the curb as I fill it I can squeeze another gallon into it. New gas tank skid a coming after the body lift. Hopefully the plastic tank with go back to shape lol.


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My only issue filling up is only being about to get 15 gallons in my tank when it's completely empty. It's been like this since my last trip to big bear and my gas tank/skid took a BIG dent to the passenger side on the rocks. If I park with my drivers tire up in the curb as I fill it I can squeeze another gallon into it. New gas tank skid a coming after the body lift. Hopefully the plastic tank with go back to shape lol.


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I noticed when I did this mod to my 06 Rubicon, that there was a plastic valve looking thing just inside the tank. The valve looked closed and I could take a screwdriver and gently push on it and it would open. Wish I had snapped a pic but was just wondering if this might be your problem? By the way the GM fuel hose fix works like a charm, I did mark the top of the hose so I could feel the top as there is limited viewing once installed. Mike
 
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My 1997 TJ has an issue at the gas station.... while filling up, the gas pump will "click off" way too soon... and I end up with only about 3/4 of a tank of gas.... After the gas dispensing nozzle clicks off I can sometimes just "barley" squeeze the handle and allow a slow trickle of gas into my tank, it takes a while but I can finally get a full tank of gas.. I'm wondering if the MOD described in this link would address my issue.
I noticed when I did this mod to my 06 Rubicon, that there was a plastic valve looking thing just inside the tank. The valve looked closed and I could take a screwdriver and gently push on it and it would open. Wish I had snapped a pic but was just wondering if this might be your problem? By the way the GM fuel hose fix works like a charm, I did mark the top of the hose so I could feel the top as there is limited viewing once installed. Mike
Sorry Frenchman I clicked on the wrong post to quote.
 
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I noticed when I did this mod to my 06 Rubicon, that there was a plastic valve looking thing just inside the tank. The valve looked closed and I could take a screwdriver and gently push on it and it would open. Wish I had snapped a pic but was just wondering if this might be your problem? By the way the GM fuel hose fix works like a charm, I did mark the top of the hose so I could feel the top as there is limited viewing once installed. Mike
Thanks, Bamacon......... I'll defiantly pay attention to any such valve in or near the tank when I "get around" to performing this mod.
 
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I found this site while searching for this exact problem for my brother in law.
He followed the instructions and the fix worked perfectly!
Thanks to the OP and Chris for posting this repair.
This repair alone convinced me to join this site.
Thanks again
 
I just bought an 05 TJ that has this fuel overflow problem. I can't find the replacement part you mention anywhere. Anyone know where I can find one?

I've exhausted my search for one. Seriously, I can't find a single place that has them in stock anymore. Your best bet is to call your local GM dealer with the part number and ask them if they can get one.
 
Thanks for the reply. Gonna try that. Too bad GM never owned up to it and fixed it. Can't believe I just bought a 2005 and someone lived with it doing that for so long.
 
Thanks for the reply. Gonna try that. Too bad GM never owned up to it and fixed it. Can't believe I just bought a 2005 and someone lived with it doing that for so long.

I feel your pain! I guess in the end we can all thank that dickhead Al Gore for making sure we have ethanol in our fuel.
 
I feel your pain! I guess in the end we can all thank that dickhead Al Gore for making sure we have ethanol in our fuel.


Say what. That needs some follow up! No fan of Al Bore but this .........
 
Feel the same about Fox News, but it's interesting. BTW - I found a place online that at least still had the part in their database. I placed an online order late last night and we'll see if I get an email saying it is actually not available or if it actually ships. I'll do another post to update this thread, just in case there are others in need of the fix.
 
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Feel the same about Fox News, but it's interesting. BTW - I found a place online that at least still had the part in their database. I placed an online order late last night and we'll see if I get an email saying it is actually not available or if it actually ships. I'll do another post to update this thread, just in case there are others in need of the fix.
Are you from the Quad Cities IA/IL?
 
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