Wrangler TJ Gas Overflow Fix

[Chris]

Do not fix the overflow problem with a GM filler hose!!!

-Moderator note-
The gas overflow and burp problems commonly experienced with 2005-06 TJs is caused by the Inlet Check Valve (ICV) sticking in the open or closed position. The correct fix is to sand down the guide tabs on the ICV and restore its ability to slide freely. This requires pulling the fuel pump to access the inside of the gas tank.

Further details are in this video and described in the quote below.

The check valve can stick down (fuel burp problem) or stick up (slow fill problem). The GM filler tube can only help with the burp problem, since it adds another flow-back flapper.

A bigger issue is that the fuel burp problem can switch to a slow fill problem when the check valve breaks free from the stuck-down position, and floats to the top, and then gets stuck there. It happened on mine. Filling up and getting burped on is no fun, but not being able to fill up at all is considerably worse. Fixing the valve is the only way to cure that.

 

[MBJ]

-Moderator note-
The GM hose is not a fix for the overflow problem. Disregard this suggestion and understand that it is preserved for historical purposes only.

The correct fix that involves sanding the check valve is found here in Post #44...

Post in thread 'Wrangler TJ Gas Overflow Fix'

Aug 31, 2016

Here is the video on YouTube. The problem is (or might be) that our ethanol blended gas may just cause this to happen again (eventually). Not sure. But it does look like a very easy fix. Wish you could get to it without dropping the tank.

• Quad City Jeep

• 

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.

 

[Chris]

Thanks for the info @MBJ!

You can get the replacement part here for a very good price:
http://www.amazon.com/gp/product/B00GUCRISO/?tag=wranglerorg-20

 

[DarkKn1ght]

I have this mod. It's nice not having fuel spill everywhere.

Sent from my SM-G900V using Tapatalk

 

[Chris]

I have this mod. It's nice not having fuel spill everywhere.

Sent from my SM-G900V using Tapatalk

I think it's probably a must have mod for all of us TJ owners!

 

[RLD123]

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.

 

[TheFrenchMan]

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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[Bamacon]

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.


Sent from my iPhone using Tapatalk

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

 

[Bamacon]

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.

 

[RLD123]

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.

 

[jgaz]

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

 

[Quad City Jeep]

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?

 

[Chris]

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.

 

[Quad City Jeep]

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.

 

[Chris]

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.

 

[Stinger]

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 .........

 

[Chris]

Say what. That needs some follow up! No fan of Al Bore but this .........

I'm not sure how much I trust Fox News, but here you go:
http://www.foxnews.com/politics/201...ethanol-blames-politics-previous-support.html

It's just one of many. Google "Al Gore Ethanol" and you'll have enough reading for weeks.

 

[Quad City Jeep]

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.

 

[Travis]

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?

 

[Quad City Jeep]

Yeah, Davenport. Got my first Jeep about 3 years ago ( a '97 TJ) and just bought a '05 TJ for my son. Will never be without a Jeep from now on.