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.

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really awful
Crashes / Fires:
0 / 1
Injuries / Deaths:
2 / 0
Average Mileage:
41,388 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 Jeep Wrangler fuel system problems

fuel system problem

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2005 Jeep Wrangler Owner Comments (Page 17 of 17)

« Read the previous 20 complaints

problem #17

Dec 152009


  • 52,000 miles


2005 Jeep Wrangler X gas tank auto-shut off malfunction the auto-shut off of the gas pump when the tank is detected as full has malfunctioned several times causing an overflow and spillage of gasoline when re-fueling. This is regardless of the gas station (company) and pump, it appears the auto-shut off is not working correctly. The vehicle is less than 5 years old and has 52,000 miles.

- Wilmington, DE, USA

problem #16

Nov 012009


  • 50,000 miles
Gas tank overflows everytime I fill the tank. Every gas station I use and any speed I try to fill the tank at. Just started about a month ago, problem will not go away, and makes me nervous about fire/personal injury every time I need gas.

- Bethel, MN, USA

problem #15

Jan 202009


  • 47,000 miles
Gas tank always spills over on the side of my 2005 Jeep Wrangler, and usually on myself. Has been a recurring problem since my first fill-up.

- Lansing, MI, USA

problem #14

Dec 012009


  • 45,000 miles


Fuel spill; during refueling there is a splash back of fuel when tank is filled. I am in fear of a fire due to the spilled fuel. And the spilled fuel is now causing damage to the vehicles paint. Also what enviromental impact is the spilled fuel having?

- Satellite Beach, FL, USA

problem #13

Jan 012008


  • miles
I own a 2005 Jeep Wrangler. When filling up the vehicle with gasoline it often doesn't register the fact that the tank is full and the gas comes pouring out. The gas leaks onto me, my Jeep and the ground. This happens every time I fill my tank. I see this as a safety issue since it's bad to get gasoline on your body/clothing, it's also damaged the paint on my Jeep in that area and the spillage on the ground is not good for the environment and a danger for others as well. Nothing has been done to correct the failure. Chrysler claims they don't see it as a "safety hazard." Of course, it is a safety hazard. There is a faulty part in the gas tank/gas tank assembly that some of us cannot afford to pay for out of pocket. In fact, why should we? it's a defect from the factory. This has been ongoing but I listed the approximate incident date as the month I purchased the vehicle.

- Easthampton, MA, USA

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problem #12

Dec 012009


  • 20,000 miles
When filling the fuel tank on my 2005 Jeep Wrangler, the tank 'spits' the fuel out of the filler neck as it nears the top. The problem started just recently. But the amount of fuel spilled is getting larger with each fill up.

- Cypress, TX, USA

problem #11

May 012009


  • 40,000 miles


After having my Jeep for 3 1/2 years, every time I fill up my gas tank (no matter what gas station) the automatic shut off does not work on the pump and large amounts of gas spill out everywhere. It did not do this for the first 3 1/2 years of owning the vehicle. Numerous other people on the internet are experiencing the same issue and it's believed to be the roll over check valve in the tank being bad. Located here is just one 14 page discussion: if this is happening with this many people it could be a major fire and environmental hazard at a gas station.

- Mascoutah, IL, USA

problem #10

Aug 012007


  • 75,000 miles
No events leading up to failure, just happened one day. It happened to me around 75, 000 miles on my Jeep, and ever since. The problem is that when I put gas into my Jeep the tank isn't venting properly, which cause gas to gush out the filler opening after the pump has automatically turn off. It doesn't matter where or when I fill up, it will do it every time unless I pump the gas is really slow. Nothing has been done to correct the part. According to other Jeep Wrangler owners they have been told by the dealer its a faulty roll valve inside the gas tank. Which requires the entire tank to be replaced. According to one dealer this is considered a normal wear item. Yet a faulty roll over valve sounds like a safety item to me. I have heard of people having this same problem with 30K miles on their Jeep.

- Woburn, MA, USA

problem #9

Dec 212009


  • 52,000 miles
When filling up my 2005 Jeep Wrangler unlimited with fuel, instead of shutting off the filler nozzle, gasoline shoots out of the gas tank filler neck spilling gasoline all over the Jeep and the surrounding area. This happens everytime I refuel.

- Chicago, IL, USA

problem #8

Dec 172009


  • miles
I own a 2005 Jeep Wrangler X model. Every time I fill up at the gas station, gas will spray profusely out of the filler neck at the same time as the automatic cutoff. I cannot fill my tank without getting sprayed. I know several people with the same model vehicle that are experiencing the same problem, so I do not feel that this is an isolated incident.

- Jacksonville, FL, USA

problem #7

Aug 212008


  • 37,000 miles


Fuel surges back out of fill tube while refueling. It happens everytime I refuel the vehicle. Huge safety factor because about a quart of gasoline gets on me, the vehicle, and the ground. Called Chrysler to complain and they will not repair the issue because I'm the second owner. I have heard of numerous Wrangler owners with the same issue.

- Pleasant Prairie, WI, USA

problem #6

Oct 012008


  • 42,000 miles
Jeep Wrangler always sprays out fuel a second or two after the automatic shutoff shuts off the pump. Fuel is sprayed on the vehicle, ground, pump, and any person standing anywhere near the nozzle. It does this at multiple gas stations, and multiple pumps. Running the pump on the slowest possible setting is the only workaround, which results in a small amount spilling on the ground. This has occurred on both my Jeep Wrangler, and has been doing it for over a year now.

- Elmhurst, IL, USA

problem #5

Dec 082009


  • miles
2005 Jeep Wrangler when filling the fuel tank it always overflows when full. It does not shut off and spills onto the ground. This did not originally do this but has happened over time on it's own. Not only is this inconvenient but it is also dangerous. After talking with other Wrangler owners an amazing amount of them also experience this problem.

- Appleton, WI, USA

problem #4

Dec 012009


  • 35,000 miles
While refueling vehicle when tank reaches almost full gas surges out of fill tube. I have heard of numerous Wrangler owners with the same problem. #1 this is extremely dangerous due to the possibility of fire and #2 cannot be friendly to our environment by spilling about a quart of gasoline on ground everytime I fill up.

- Pleasant Prairie, WI, USA

problem #3

Jul 152008


  • 25,000 miles
Starting at approximately 25000 miles, gas began spilling out of the filler nozzle during refueling. This occurs regardless of station location. The Jeep was brought to a mechanic who claimed it was an issue inside the tank. No repairs have been made at this time. Problem still occurs.

- Alexandria, VA, USA

problem #2

Dec 012009


  • 53,000 miles
Jeep Wrangler have a common issue when filling the gas tank. For whatever reason (bad pressure release valve?) filling the tank will often result in fuel squirting back out the filler neck once it is full. This happens suddenly, and fuel shoots back out a good distance, causing a potentially hazardous condition. I've spoken with many other Jeep Wrangler owners that are experiencing this issue.

- Lakewood, WA, USA

problem #1

Dec 212008


  • 25,000 miles
I cannot fill my gas tank full without gas coming out spilling on the vehicle and on me. I own a 2005 Jeep Wrangler. It only has 25,258 miles on it. When I purchased the vehicle I did not purchase an extended warranty. I spoke to Chrysler motors Corp customer center (1-800-992-1997) (ref. #18329606) on February 10, 2009 about this safety issue. I am requesting that Chrysler repairs the gas tank for me because lives are at danger when the vehicle is filled up with gas and gas comes out of the tank. Gas is getting on the vehicle, my hands and the ground at the pump. Armbruster motor co. (1-800-766-0980) informed me on February 6, 2009, the only way to correct this issue was to purchase a new gas tank. The cost of a new gas tank would be around $500. Chrysler told me that they will not pay for a new gas tank but if I pay for the new gas tank they would cover the new tank for 12 months or 12,000 miles. I believe Chrysler should pay for this repair because they designed the faulty gas tank that was originally placed on the vehicle. This is an extremely dangerous situation when I fill my vehicle with gas. It is not like the radio doesn't work, spilled gas is a fire hazard. Thank you, jennifer willman

- Falls City, NE, USA

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