Gas tank overflow

Collapsed or plugged vent line?

Hadn't thought of that. I'll check it out. Thanks.

FRH

Had varying problems with splash and early cutoff. Usually places with full tanks or newer high-flow pumps. My solution was to turn the pump handle sideways... dunno why, but it works better that way on some pumps.

Generic answers: Not sure how yours is set up.

Splash when the tank is full: The backflow sensor is in the pump and measures backpressure. You might have a loose vent line so the backpressure isn't building fast enough for the pump to shut off. That or someone isn't calibrating the pumps properly.

Splash when the tank is not full or the tank is hard to fill: Stuck fill rollover valve Stuck vent rollover valve Crimped/crushed vent line. Although the rollover valves are hard to get stuck unless you have been rolling the jeep over. :) Crushed vent lines are usually the result of a big rock and no skidpan.

It's a splash when tank is full situation. The vent line sounds like the culprit. No one else is having this problem that I could see at the stations I use. Thanks. Sounds like a trip to the Jeep dealer. :-(

FRH

Not necessarily. If you can locate the overflow hose, run a soft wire (like aluminum fence wire) up the hose and see if it opens things up. The overflow hose is usually routed from the top of the tank to run part way down the side - look for a 1/4" inch or so hose just ending on the side of the tank - not sure where it actually runs on your Jeep.

Unfortunately everything is mounted on the top of the gas tank according to my Daimiler-Chrysler shop manual. Nothing accessible unless "The fuel tank must be lowered ..." and that's not happening in my driveway. :-) I believe the culprit is the On-Board Refueling Vapor Recovery system (ORVR). I shouldn't complain. At almost 84k, aside from normal service, I've only had to replace the sway bars and one u joint on the front drive shaft. It runs great so I'll put a few $$ into it. And it's been paid off for over three years. :-) Thanks for all the suggestions.

FRH

I had this problem in my Honda and it was the fuel cap. They are cheap, too.

Earle

Turned out to be a crack in the gas tank. Not enough pressure to activate the automatic shut off on the gas pump. Just had the new tank installed today at the dealer. Problem solved, but not cheaply. :-(

FRH

Interesting that a crack large enough to cause the problem you were having wouldn't cause the check engine light to come on due to an evap system leak. Did they show you the crack?

Yeah, they offered me the old tank. I looked at it. Crack starting at the fuel pump seal. And the new tank fixed the problem. No more splash back when I fill the tank.

FRH

P.S. Happy Thanksgiving everyone!

FWIW fuel kickback like you experienced is a pretty common problem with the TJs. I have read more about it than I ever wanted to and the solution so far has been to replace the fuel tank. The strange thing is, the new part number is the same as the old one in some cases.

On vehicles with current warranty the manufacturer was replacing the tanks. Some folks were able to get it replaced even after warranty, depending on the generosity of each particular dealership.

A TSB has been issued, and many of us have filed a complaint in the hopes that a recall would be issued.

On a final note, after replacing the tank, the issue has presented itself again in some cases, so keep an eye on it.

K.

Consumer reports 2010

This is my third Jeep and the problem only started this summer on this Jeep ('06 Wrangler). The tank was cracked. The tech showed it to me. Problem solved. You can be sure if it starts happening again the dealer will hear about it. That's one reason I had a Jeep dealer fix it instead of the local shop I use for "generic" repairs. It will become a Jeep problem. :-)

FRH