Problem while pumping gas

[DropTopDon]

Have an 04 and recently whenever I try to get gas, the pump stops pumping gas as it does usually when the tank is full if one were to start topping off the tank. The pump just stops pumping gas and clicks. I experimented with several different gas stations and pumps to make sure it wasnt just malfunctioning gas pumps. It is almost as if I have to find that sweet spot for the gas to maintain a steady flow into my tank out of the pump without clicking and stopping. What could be the reason for this?

 

[DEValken]

See this thread - there is a sticking valve in the system...

https://wranglertjforum.com/threads/wrangler-tj-gas-overflow-fix.244/

 

[Blondie70]

Mine does the same thing. Just put a tank in and no valves are sticking. I have to angle the nozzle around until it's happy then it goes in full speed ahead.

 

[DropTopDon]

See this thread - there is a sticking valve in the system...

https://wranglertjforum.com/threads/wrangler-tj-gas-overflow-fix.244/

I took a look at it, but my gas does not overflow out of the neck nor splash back at me. It seems like it just does't want to let gas in out of the pump and causes it to click.

 

[L J]

I took a look at it, but my gas does not overflow out of the neck nor splash back at me. It seems like it just does't want to let gas in out of the pump and causes it to click.

The sticking valve has two symptoms. The first is splash back caused by the valve stuck in an open position. The second is slow fill caused by the valve stuck in a close to closed position.

 

[OHFIVETJ]

Try filling up at different fuel levels, like adding fuel @ 1/4 tank or 1/2 tank / don't run it down to empty. Sometimes too much air in the tank will force shut off & a poor pump angle of entry too. This has also mitigated spit back as well.

 

[ktugboat42]

I just pull the nozzle out a bit and it seems to work fairly well.

 

[Jodh]

Do the real fix and take the overflow valve out and sand it down. Mine would only take about 1\4 gallon then would shut off. Took forever to fill up. Fixed mine 3 yrs ago and haven't had a problem since.

 

[jinciarrano]

The sticking valve has two symptoms. The first is splash back caused by the valve stuck in an open position. The second is slow fill caused by the valve stuck in a close to closed position.

My 05 has always spilled over. Now though I am having the OP issue of having to drizzle my gas in not even at first click.
Is there a fix for this? Wire down the fuel line to loosen the valve? Or replacing the line/valve completely

 

[DuckNut]

My 05 has always spilled over. Now though I am having the OP issue of having to drizzle my gas in not even at first click.
Is there a fix for this? Wire down the fuel line to loosen the valve? Or replacing the line/valve completely

You have to drop the tank, remove the pump, remove the check valve, sand the 3 little tabs down a weed bit and put it all back together.

While you are in there, you will find another hose. This hose is the vent tube. It is currently about 6 inches long. If you cut it so it is about an inch long (cut 5 off) you can get an additional 3 gallons in the tank.

 

[L J]

My 05 has always spilled over. Now though I am having the OP issue of having to drizzle my gas in not even at first click.
Is there a fix for this? Wire down the fuel line to loosen the valve? Or replacing the line/valve completely

 

[sab]

While you are in there, you will find another hose. This hose is the vent tube. It is currently about 6 inches long. If you cut it so it is about an inch long (cut 5 off) you can get an additional 3 gallons in the tank.

Are you sure? I know that the older 15 gallon tanks can be converted to 19 gallon tanks by cutting the vent tube off, but I've never heard of a 19 gallon tank, which the OP should have in his 04, being modified to fill more.

 

[OldBuzzard]

My 05 has always spilled over. Now though I am having the OP issue of having to drizzle my gas in not even at first click.
Is there a fix for this? Wire down the fuel line to loosen the valve? Or replacing the line/valve completely

Both the spill-over and won't-fill are caused by the same valve sticking. If it sticks down, it causes spill-over. If it sticks up, it causes won't-fill. And the nasty little beast can occasionally slip to the other position. My 05 did the same thing yours did. Both require the same fix, the "Real Fix" in the linked thread (#2 above).

 

[DuckNut]

Are you sure? I know that the older 15 gallon tanks can be converted to 19 gallon tanks by cutting the vent tube off, but I've never heard of a 19 gallon tank, which the OP should have in his 04, being modified to fill more.

My 06, I have never been able to get more than 15 gal in until I cut that hose about 3 years ago when my valve was sticking. Even though the manual specs said 19, I never was able to achieve that much. So I presume that the hose was limiting the amount and now I can put more than 15 in it.

I took thought the 15 gal was pre 97 and 19 gal was post 98...just not the case with mine.

 

[sab]

My 06, I have never been able to get more than 15 gal in until I cut that hose about 3 years ago when my valve was sticking. Even though the manual specs said 19, I never was able to achieve that much. So I presume that the hose was limiting the amount and now I can put more than 15 in it.

I took thought the 15 gal was pre 97 and 19 gal was post 98...just not the case with mine.

Are you aware that, on E, the 19 gallon tank typically still has 3 to 4 gallons left in it? That would make it seem like it only holds 15 gallons...

 

[Link]

Are you aware that, on E, the 19 gallon tank typically still has 3 to 4 gallons left in it? That would make it seem like it only holds 15 gallons...

I had to do the gas flow (splashback in my case) fill issue fix on my 2005. I ran the tank to the point of the low gas light on and then dropped the tank. I pulled the fuel pump and then pumped out the remaining gas into a gas can. (I didn't want to work with liquid gas in the tank and wanted to lift an empty tank instead of one with some gas in it when reinstalling it into the Jeep) It was between 3-4 gallons.

I generally refill at the 1/2 point but it's nice to know I have that much gas left before it stops moving.

 

[sab]

I just opened up the spare tank I have for my 2005 LJ and took pictures of what's inside, and there is nothing that can be trimmed to get more capacity. Here's what's inside:

Note that the doohickey in the upper right is the assembly that needs to be removed, modified per the post/video earlier in this thread, and reassembled to stop the filling issues.

 

[LONGJP2]

My 06, I have never been able to get more than 15 gal in until I cut that hose about 3 years ago when my valve was sticking. Even though the manual specs said 19, I never was able to achieve that much. So I presume that the hose was limiting the amount and now I can put more than 15 in it.

I took thought the 15 gal was pre 97 and 19 gal was post 98...just not the case with mine.

That doesn't sound right.