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:
0 / 0
Injuries / Deaths:
2 / 0
Average Mileage:
62,514 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 16 of 23)

« Read the previous 20 complaints

problem #144

May 052010

Durango 4WD 8-cyl

  • miles


Gas overflows on my 2005 Dodge Durango when filling up. Happens every time. Have gone to local dealership and contacted customer service online and both have said my VIN# doesn't fall under their previous recall.

- Rock Hill, SC, USA

problem #143

Apr 302010


  • 96,740 miles
Every time I fill up my gas tank using the auto fill at the gas station, whenever the nozzle shuts off gas shoots out. This happens every time I fill up. I went online and looked up this problem and have found many people have this problem and that a recall was even issued. Armed with this information I went to my local dealer. I was then informed that my vehicle is not covered under this recall. My vehicle was manufactured Mar 05. I will also be calling Chrysler and complaining to them. I feel this needs to be looked into since multiple years and even 05 cars on covered in the recall are suffering from this problem.

- Jackson, MO, USA

problem #142

Aug 242009


  • miles
When filling gas tank, fuel pump shuts off when full, then gas is expelled from the tank. My car was manufactured in Dec 04 and the recall covered cars manufactured through Nov 04. Is there any recourse or appeal available to get this recall extended. Clearly Dodge didn't solve the problem as soon as they think they did, judging by the hundreds of us with the same problem.

- Rochester, MN, USA

problem #141

Apr 012009

Durango 4WD 8-cyl

  • 70,000 miles


Fuel leakage out of the filler neck at the end of refueling. This happens fairly often when filling the gas tank of my 2005 Dodge Durango. Gas spills out of the filler neck onto the side of the vehicle and the ground. Note that recall campaigns 09V003000 and 05V034000 describe this issue exactly but Chrysler says the recall does not apply to my vehicle. I brought my vehicle in to a Dodge dealer and they diagnosed the issue as a faulty check valve.

- Brookline, NH, USA

problem #140

Mar 272010


  • 72,000 miles
Fuel spills out when filling fuel tank. Current recalls from Chrysler are Chrysler recall E01 and H45. NHTSA recall 09V003000. Vehicle has been inspected by local dealer, linder Dodge, new london ct. Fuel tank problem determined to be same as recall. As of 04/19/10, Chrysler wants me to pay $260 for replacement of fuel tank. 2005 Dodge Durango SUV. I know of someone else who has similar situation on an 2005 Durango, manufactured 12/04. My Durango was manufactured 03/05. The fuel spill problems has been occurring over past 5 months. Why should I have to pay for a Chrysler defect, when others don't have to pay? I have had fuel spill on me.had to stop what I was doing, go home, and change clothes, along with deal with deal with odor of fuel inside of vehicle. I understand my build date is out of recall date of manufacture, that I have hard copies for. But it seems the recall needs to be expanded, because the defect is occurring in a larger number of vehicles.

- Niantic, CT, USA

problem #139

Apr 132010

Durango 4WD 8-cyl

  • 38,000 miles
I just bought a used 2005 Dodge Durango and when I fuel the pump wont stop and gas comes out of the filler tube all over the ground. The dealer says that my VIN is not covered but I have found at least 500 other people online with the same issue with the fuel but not the correct VIN.

- Eau Claire, WI, USA

problem #138

Jan 012009


  • 43,000 miles


I own a 2005 Dodge Durango with 5.7 lt. Hemi.. every time I put fuel in the vehicle gas sprays out onto the ground. I did some research on the problem and found that there was a recall for this problem.. I took the vehicle to a Dodge dealer to have this issue addressed. The dealership ran the VIN and advised me that. The gas spillage issue can be resolved but it will not be covered by Dodge because the VIN does not fall into the recall range.....I called Dodge and advised them of the problem only to receive no help.

- Northampton, PA, USA

problem #137

Nov 242009

Durango 4WD 8-cyl

  • 59,000 miles
1. the car requires gas. 2. when filling, gas shoots out of fill pipe when full. (1-2 cups) 3. problem same as described in action #RQ08005 and recall campaign# 09V00300 but my VIN not included in recall.

- Grand Rapids, MN, USA

problem #136

Dec 052009

Durango 4WD 8-cyl

  • 20,000 miles
2005 Dodge Durango, fuel spill out when filling tank, happens virtually everytime. It gets gas all over the side of the vehicle and anyone near the gas pump. There has been a recall on this, but my VIN is not part of the recall.

- Tobias, NE, USA

problem #135

Jan 012010


  • 44,000 miles
Gas tank filler neck. A vehicle recall was issued for leaking gas when fueling. Dealer checked and stated car was fine and not effected. Since I have filled vehicle (3) times and (2) of those time gas has come out of the filler neck with so much force it splashed all over me and surrounding equipment. Incident happened before inspection as well and Dodge was told about it at time of service but they still stated no issue existed. The tank is defective, and appears to be getting worse. Posses a large threat of ignition when gas and gas vapor shoots on the person pumping gas. Inspection method is inadequate and not working. Issue is still present and Dodge is not fixing the recall even though a issue exists.

- Fort Myers , FL, USA

problem #134

Mar 012010

Durango 4WD 8-cyl

  • miles


Fuel filler check valve does not work. Gasoline will spray out of car when topping off.

- Littleton, MA, USA

problem #133

Nov 272009

Durango 4WD 8-cyl

  • 68,000 miles
I have a 2005 Dodge Durango VIN# [xxx]. it has 71,000 miles on it. When filling the gas tank, it blows the gas back out the filler neck every time I close the pump nozzle to stop filling the tank. Everytime I stop pumping gas it blows approximately a half gallon of gas all over me, the ground, gas pump, vehicle, and whatever else is around. This a very dangerous situation. It has the potential to catch fire and burn down the gas station, vehicle, and innocent by-standers etc. It also has the potential to get into the water through run off. I brought the vehicle to a Dodge dealer to find out what was wrong with it. They told me that it was a faulty check valve in the filler neck and that the whole gas tank had to be changed. They also told me that there was a recall on some Durangos for the same exact problem but, the recall did not cover my VIN#. I don't have the $650 to fix it. I am hopeful that the recall would be expanded to cover my vehicle and all the other I found on the internet. Those that are having this problem and are not cover under the recall are just as dangerous as the vehicles that are covered. Information redacted pursuant to the Freedom Of Information Act (FOIA), 5 U.S.C. 552(B)(6).

- Opelousas, LA, USA

problem #132

Mar 292010


  • 95,000 miles
My 2005 Dodge Durango has a problem where about 3-6 cups of fuel comes spewing from the filler hole when the fuel tank is filled. This "spewing" occurs just after the fuel nozzle "clicks" off signifying that the tank is full. The fuel spills all over the ground and surrounding people. It happens every time I refill the truck. I found on the NHTSA website that other Durango's are being recalled for this problem under NHTSA recall 09V003000 and 05V034000. I called Chrysler and they told me my particular vehicle was not recalled and therefore I was responsible for the repair. My dealer, orange park Dodge, diagnosed the problem as the filler tube inlet check valve which is the same part recalled on other 2005 Dodge Durangos. I am currently waiting for the part to come in before it can be replaced. Since Chrysler is changing the part for free on recalled vehicles, but my 2005 Durango with the same problem is my responsibility. This is a safety hazard. I was also informed by the dealer that the tank would leak out in a roll over accident since the check valve is not closing as designed.

- Jacksonville, FL, USA

problem #131

Mar 282010


  • 43,500 miles
I own a 2005 Dodge Durango which I bought new and now has 43500 miles. For the past month, everytime I fill up the gas tank at any station and pump, the pump shuts off correctly and then gas comes pouring out of the tank onto anyone standing close and runs down the car onto the ground. I would estimate about 1-2 cups of gasoline come back out of the tank. I see this as a very dangerous situation. I contacted the dealership which told me that they have had multiple owners with the same problem with this vehicle platform but there has not been any recall safety or otherwise. So I thought I should contact NHTSA to investigate this situation.

- Normal, IL, USA

problem #130

Jan 042010


  • 44,000 miles
When filling up the fuel tank in my 2005 Dodge Durango, gas would spill/splash out of the tank instead of stopping when full. We finally took it to our local Dodge dealer and they said we needed a new gas tank as some "flow" related part within the gas tank was bad. The solution was to replace the entire gas tank. When the dealer attempted to find a part, they informed me it would take a month for the part to come in as there were over 100 on back-order, all related to the same issue. It seemed odd to me that a less-than-5-year-old car with only 40,000 miles on it had to have its gas tank replaced, but it seemed more odd that there were over 100 others at a minimum like me awaiting the same part. Seems like this is a defect in the way the original equipment was built and/or installed.

- Lone Tree, CO, USA

problem #129

Jun 012009


  • 95,000 miles
At the conclusion of filling my vehicle with gasoline following the gas pump nozzle automatic shut off, approximately 8 ounces of gasoline spews from the fill nozzle onto the ground. This began occurring 9 months ago. Prior to that time it never occurred. I have have driven the vehicle since it was new. This is not in intermittent occurrence. Once it began exhibiting this behavior, it does it consistently every time the tank is filled.

- Mattawan, MI, USA

problem #128

Mar 212010


  • 45,000 miles
Ref my 2005 Dodge Durango. The fuel tank filler tube inlet check valve will not fully close at the end of refueling. This allows fuel to escape from the vehicle through the filler neck at the end of refueling. Fuel leakage in the presence of an ignition source can result in a fire.

- Crestwood, KY, USA

problem #127

Nov 242009


  • 42,000 miles
There is no particular event leading up to the following failure--it happened and then never stopped happening. Every time my 2005 Dodge Durango is refueled, the gasoline backwashes out of the filler tube. A significant amount of fuel gushes out of the filler tube requiring that I Dodge the fountain of fuel. This is a serious safety issue. My research revealed that a recall had been placed on this model for the same symptoms, but Dodge claims that my VIN isn't wasn't included in the recall. They suggested I take it to a local dealer for a diagnostic, which cost $70. The diagnosis is that the charcoal evap canister is filled with "liquid" caused by overfilling the tank and Dodge refuses to cover the repair. I contend that the evap issue is caused by the very problem of the fuel backwash. My visit to revealed that the fuel overflow is a common problem. Given the existing recall, it's obvious this is a safety problem that Dodge should be required to correct.

- Melbourne, FL, USA

problem #126

Jun 012009

Durango 8-cyl

  • 60,000 miles
I have a 2005 Dodge Durango VIN#[xxx] built 09/04 that when I fill up the gas tank gasoline spits back before the pump shuts off. There is a Chrysler recall (E01 and H45) and my vehicle was manufactured during the recall dates. Chrysler continues to deny that the vehicle is not part of the recall but has offered a "good will replacement" which costs me $100 out of my pocket. My Chrysler case/reference # is [xxx]. the local dealer verified that the defect with the tank was the same as the recall. The NHTSA action # is RQ08005. There is a high potential of fire, property damage, and death or injury to who ever is near the vehicle while fueling. Information redacted pursuant to the Freedom Of Information Act (FOIA), 5 U.S.C. 552(B)(6).

- Keller, TX, USA

problem #125

Mar 012010


  • 41,000 miles
When filling the gas tank on my 2005 Dodge Durango. The gas does not automatically shut off causing an overflow every time. This is the exact thing that is described in a recall for '05 Durangos however mine does not have a qualifying VIN #. my vehicle has 44,000 miles on it. I contacted Chrysler, due to not being covered under warranty or the recall they said it was my financial responsibility to get the problem diagnosed and repaired by the dealership. Chrysler stated only after that was done they would look into if further but could not assure me they would cover any of the repair bill. I have not had this done as I cannot afford the up front expense. For the meanwhile I do not fill my tank all the way.

- Albany, NY, USA

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