Huge win for car owners! All TSBs to be made public. The Center for Auto Safety just made the NHTSA (US Government) make public the full text of all TSBs from now on. They are the same organization that has petitioned the NHTSA & filed lawsuits to protect car owners over exploding gas tanks & other major safety issues. Whenever you drive in your car, you are safer thanks in part to a lot of work over the years by this small but very effective consumer advocacy group.

Please take a moment & say thank you by donating $5 or whatever you can to the Center for Auto Safety. Notes: The second generation Durango was introduced in 2004 and instantly came under fire for, well, catching on fire.

From 2004-2006 electrical overloading in the driver's side instrument panel caused numerous reports of interior fires. The interior infernos became so commonplace that Chrysler eventually issued a recall.

The problems didn't stop there, however. Owners of the recalled vehicles complained about being treated unfairly and given take-it-or-leave-it low ball settlement offers. "They offered me $2000 under NADA retail as a settlement," said one owner, "and have been rude and hostile to deal with." Nothing says awesome service like treating your customers rudely after their cars have already caught on fire.


really awful
Crashes / Fires:
1 / 0
Injuries / Deaths:
2 / 0
Average Mileage:
81,910 miles

About These NHTSA Complaints:

This data is from the NHTSA — the US gov't agency tasked with vehicle safety. Complaints are spread across multiple & redundant categories, & are not organized by problem.

So how do you find out what problems are occurring? For this NHTSA complaint data, the only way is to read through the comments below. Any duplicates or errors? It's not us.

2005 Dodge Durango fuel system problems

fuel system problem

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2005 Dodge Durango Owner Comments (Page 4 of 7)

« Read the previous 20 complaints

problem #79

Apr 082013

Durango 8-cyl

  • miles


When filling the tank, the pump shuts off and gasoline continues to spill out. This has happened on numerous occasions and we have to avoid topping off the tank in order to avoid the spill. When doing some research, we found that there was a recall in 2009 for the fuel system/gasoline storage tank assembly. Today (4/8/13), we contacted and spoke to our Dodge/Chrysler dealer and they stated that there was indeed a recall in 2009 and apparently our vehicle VIN was not covered under the recall and that there were no extensions. We are just in awe, that a potential fire hazard and something this dangerous would not continue have an extension under the recall. Had we known there was a recall, we would have had the situation addressed sooner.

- Bristol, CT, USA

problem #78

Apr 052013

Durango 8-cyl

  • 68,000 miles
My 2005 Dodge Durango had the completed recall H45 worked done on 4/27/2009. The Dodge dealership replaced the gas tank per the H45 recall. The Dodge dealership considers the matter closed but the issue has now occurred with this new installed tank. The vehicle had 28,994 miles when this work was done. Now the vehicle has 68,000 miles on it and the same issue occurs while filling the gas tank up. Upon shut off of the gas pump, fuel will spit up out of the inlet fuel tube and leave fuel on the side of my SUV and leave a puddle of fuel below the car. I wanted to report this issue asap due to the fact that recall H45 was completed on this vehicle but problem is occuring again. Under the recall H45 the dealer will replace the fuel tank, but what about the inlet fuel check valve" was the tank inlet check valve replaced when the fuel tank was replaced? was the fuel tank replaced on my SUV a newer unit that passed all safety checks or did I get an older unit that still had the issues with the inlet check valve failing" this issues needs further investigation to meet the safety recall H45 completed work done by the dealer and to help others that may have the same issue occuring once again with there Durangos under this recall.

- Centerburg, OH, USA

problem #77

Mar 282013

Durango 8-cyl

  • 125,064 miles
Each time I fill the vehicle with fuel it spits back up through the filler tube and all over the side of the vehicle. The pump then shuts off. I have notified two fuel stations of this at the time I filled the vehicle thinking it might be a pump problem, but I researched and many vehicles of this model have reported this to be a problem. There is a strong odor of fuel in and around the vehicle at the time of fill up and there after. Active recalls do not appear to cover my vehicle, but the problem is there and obviously needs to be repaired. My dealership has been contacted.

- Nine Mile Falls, WA, USA

problem #76

Mar 142012

Durango 8-cyl

  • 90,000 miles


The contact owns a 2005 Dodge Durango. The contact stated that while refueling, gasoline spewed from the filler neck without warning. The vehicle was taken to the dealer where it was advised to the contact that the fuel tank would possibly need to be replaced but a diagnosis was required. The manufacturer was made aware of the failure and stated that the vehicle was previously repaired under NHTSA campaign number: 09V003000 (fuel system, gasoline) in 2005. The vehicle was not repaired for the recent failure. The approximate failure mileage was 90,000 and the current mileage was 99,000....updated 04/25/13 the consumer stated dealer advised the manufacturer that the vehivcle had two leaks that were causing the failure. The dealer claimed the second leak was unrelated to the first leak. The consumer has a video clip of the failure. Updated 05/17/2013

- Salinas, CA, USA

problem #75

Nov 122012


  • 88,000 miles
The contact owns a 2005 Dodge Durango. The contact stated that fuel spilled from the filler neck while refueling. The vehicle was taken to the dealer for inspection, who stated that the vehicle was previously serviced for the failure under NHTSA campaign number: 05V034000 (fuel system, gasoline) in 2005. The manufacturer was notified but offered no assistance for the failure. The vehicle was not repaired for the recurring failure. The failure mileage was 88,000.

- Fayetteville, AR, USA

problem #74

Feb 252013

Durango 8-cyl

  • 99,200 miles
I received a letter recently from my local Dodge dealer indicating my 2005 Dodge Durango would require repair for something causing the fuel to spill out during fill up. This has happened to me several times in the past as I was unaware that there was a recall for this. After receiving this letter a few weeks ago I inspected the quarter panel underneath the gas tank more closely noticing bubbling of the paint with chipping starting. Pressing on the paint it sounded corrosive like rust. As I began to chip some of the paint away I discovered rust and two holes that were completely through. Looking through the holes I could see rust behind the body. After reviewing several car and Dodge forums I see that this has happened to several people in the same area of the drive quarter panel. I can only assume there is a correlation between the fuel problem and the rust that appears to have come inside out to the body of the car. There is no other rust on this car and has been well maintained. I contacted my local dealer who informed me that the recall on the inlet valve is still valid however rust would not be. It concerns me that Chrysler doesn't feel responsible for the damage caused by their defective item. How could I have know that this was happening since I just received notification I'm concerned the rust damage is more great than I can actually see. Of course I'm additionally concerned with possible fire etc which is what the recall specifically indicates. I will make appointment with the dealership for repair of the fuel inlet valve.I would like Chrysler to also pay for the damage that was caused by their defective part. I have 99,200 miles currently. I don't want my concerns to be dismissed as I feel I'm not the only one that this has happened to. I only received a letter recently for this problem so I feel all parts of the problem should be addressed.

- Lexington , NC, USA

problem #73

Feb 262012


  • 109,000 miles


The contact owns a 2005 Dodge Durango. The contact stated that fuel spilled out from the filler neck while refueling. The vehicle was not taken to the dealer for inspection. The manufacturer was notified who stated the VIN was not included in NHTSA campaign number: 09V003000 (fuel system, gasoline). The vehicle was not repaired. The failure mileage was 109,000.

- Waukegan, IL, USA

problem #72

Feb 212013

Durango 8-cyl

  • 124,000 miles
I filled my 2005 Dodge Durango today with gas and the nozzle clicked and gas spewed out all over me and my nine year old son this is unsafe needs attention right away.

- Peabody, MA, USA

problem #71

Feb 192013

Durango 4WD 8-cyl

  • 119,000 miles
Vehicle stalls at low speeds and deceleration, idling hard at a stop and while in park, will stall when idling hard, gas spills out of inlet when filling up completely, sluggish in temperatures below 30 degrees and above 80 degrees, requires more than normal maintenance, service tech's can never diagnose the causes of stalling or idling issues, think it might concern the throttle body, transmission has torqued itself out before, stripped screws, rebuilt at 90000 miles. Just waiting for it to go again. This vehicle has been nothing but issues ever since I bought it used. Every fix just feels like a band aid to the manufacturing problems it has.

- Elkhart, IN, USA

problem #70

Dec 052012

Durango 8-cyl

  • 129,000 miles
I purchased a used 2005 Dodge Durango and recently in December 2012 it started having problems when trying to put gas in it. The gas pump clicks off and the the gas starts to spew back out not only does it go on the car it actually even reaches you. There has been recalls for this year Durango but I was told my VIN number was not covered. Since this problem I have been doing some research and have found out that over 3,000 people also have complained. I believe this is a very dangerous situation and they say it can cause a fire. I dont understand why the NHTSA would not recognize and demand there be more recalls done and honored free of charge. A life is a life and cant believe anyone would take a chance with it.

- Barbourville, KY, USA

problem #69

Aug 182012

Durango 4WD 8-cyl

  • 120,112 miles


After purchasing the vehicle used as is, I took the vehicle to completely fill the tank. As the tank became full the pump handle clicked and fuel began to overfill out of the spout. Fuel sprayed along the side of the Durango and on to my clothes and shoes. I am not happy with the dangers that are possible with this spilling. After doing much research I have came to the conclusion that it is the check valve inside my gas tank. I cannot afford to replace the tank and feel it is the responsibility of Dodge to pay for this. They have told me I am not covered under the recall but I feel this is unfair.

- Beloit, WI, USA

problem #68

Jan 232010


  • 40,000 miles
The contact owns a 2005 Dodge Durango. The contact stated that when he attempted to stop refueling, fuel spilled out of the vehicle. The vehicle was taken to the dealer for diagnosis and the fuel cap was replaced but the failure recurred. The failure recurred two additional times after the initial repair. The dealer informed the contact that the vehicle was not included in NHTSA campaign id number: 05V034000 (fuel system, gasoline:storage:tank assembly:filler pipe and cap). The manufacturer was not notified. The vehicle had not been repaired. The failure mileage was 40,000 and the current mileage was 75,000.

- Waterbury, CT, USA

problem #67

Dec 282009

Durango 4WD 8-cyl

  • 50,000 miles
Check engine lite came on and the code was large leak loose gas cap so I replaced it and it worked for two weeks and it happened again. Since then its been a problem. I see they had a recall on Dodge Durangos that were made in 3/1/04 to 11/16/04 for filler pipe and cap I purchased my Dodge Durango on 12/2004 it was made in Aug or Sept of 2004. They told me it was not on the recall list but I am having the same problems that the Dodge recall was having. Thank you hope you can help.

- Waterbury, CT, USA

problem #66

Dec 052011


  • 90,000 miles
The contact owns a 2005 Dodge Durango. The contact stated that whenever the vehicle was refueled, gasoline would spill from the fuel tank. The contact took the vehicle to the dealer and inquired about NHTSA campaign id number: 09V003000 (fuel system, gasoline: Storage: Tank assembly), but the manufacturer stated that the vehicle was not included in the recall campaign. The failure mileage was 90,000 and the current mileage was 110,000.

- East Moline, IL, USA

problem #65

Oct 242012

Durango 4WD 8-cyl

  • 125,000 miles
I bought this vehicle used and every time I try to fuel it up, it spits out gas and the pump shuts down after the gas is already coming out.

- Cuyahoga Falls, OH, USA

problem #64

Sep 222012

Durango 4WD 8-cyl

  • 65,000 miles
Each time I fill the gas tank, if the nozzle is set to automatically shut off, the nozzle shuts off, however fuel overflows the filling tube. Often it runs down the side of the vehicle and/or splashes out. I contacted Chrysler about a recall in place for these symptoms, however, they said my vehicle is not included.

- Farmington, MN, USA

problem #63

Jan 012012


  • 120,000 miles
The contact owns a 2005 Dodge Durango. The contact stated that after refueling the fuel tank, gasoline would spill back out from the filler neck. The vehicle was taken to a dealer where they advised him that the fuel tank failed and needed to be replaced. The vehicle was not repaired. The manufacturer was not contacted. The contacts vehicle was repaired under NHTSA camapign 05V034000 (fuel system, gasoline:storage:tank assembly:filler pipe and cap) prior to the recent failure however, the repair did not correct the failure. The failure mileage was approximately 120,000. The current mileage was approximately 176,000.

- Coolage, AZ, USA

problem #62

Dec 152012

Durango 4WD 8-cyl

  • 81,732 miles
Every time I fill the gas tank, the gasoline spit out at the end of filling.

- Harvard, IL, USA

problem #61

Dec 042012

Durango 8-cyl

  • 98,500 miles
This is getting ridiculous and it seems that no one is willing to take ownership for a faulty system that is obviously dangerous. What I found to be absurd is how multiple people have posted numerous complaints about the same issue, recalls have been made for the same issue and still no action. I have a 2005 Dodge Durango and each and every time I fill my tank the pump will stop but an excessive amount of gas will overflow. How many complaints must be entered before someone takes action or are manufacturers waiting for a catastrophic mishap to get their attention. Fumes could easily get under the vehicle, and find the catalytic converter and ignite. Something must be done, the time is now. Take responsibility!

- Alexandria , VA, USA

problem #60

Dec 232012

Durango 4WD 8-cyl

  • 58,650 miles
When I fill my gas tank I get a very strong gas smell, the cab fill with gas fumes. You can only smell gas on the drivers side I brought it in 3 times to be looked at but not issues can be found. The odometer says "gas cap" but the dealer finds no code issues. There is clearly a issue with my Durango but no one is willing to help me with it!! Dodge said that my Durango is not included in the recall notice and they are more than willing to hook it up to there computer for $100 bucks! I have had this Durango since 12/2212 and have been working with the private dealer that sold it to me he is not able to find anything wrong with it. I am only getting 7-10 miles per gallon that is crazy. Im not sure what to do.

- Milton, VT, USA

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