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 19 of 23)

« Read the previous 20 complaints

problem #84

Apr 102009


  • 114,000 miles


My 2005 Dodge Durango limited (hemi) spews about 1 quart of gas out of the filler tube every time I fill up with gas. Dealer says my VIN # ( mfg. Date 3/05) is not covered by their 1st or 2nd recall. I called Chrysler's customer care @ 1-800-853-1403 and was told although I appear to have the problem associated with the recall, they will not do anything because my vehicle now has 150,000 miles on it. The problem started approx. April 2009. I have learned to stand to the side when I fill up so I don't get drenched with gasoline when I fill up !

- Wilmington, NC, USA

problem #83

Dec 122009


  • 60,000 miles
Anytime I fuel, my J2005 Durango spits a lot gasoline out of the filler neck. It does not matter how fast I fuel or whether or not I top off the tank. I called Dodge and was told that Chrysler/Dodge will not include my 2005 Durango vehicle in the fuel tank recall as noted in your campaign number 09V003000 or 05V3400, even though I had the same issue the recalls were to fix. I was told my mileage was to high to be included in a recall. The first incident was in Feb of 09 & now it is every time I fuel.

- Athens, TX, USA

problem #82

Dec 252009


  • 57,000 miles
When fueling the vehicle, after the pump has shut off, fuel will shoot out of the fuel fill hole. This has done this repeatedly, and is to the point where it does it everytime the vehicle is filled up. When this happens, fuel is all over the ground, shoes, pants and anything else near the fuel cap. This is beginning to concern me as this is an extreme fire hazard. Recalls for the 2005 Dodge Durango were researched and our particular VIN# is not under the recall list. No repairs were attempted. Date listed below is the last time this incident happened.

- Cape Girardeau, MO, USA

problem #81

Jan 012008


  • 49,000 miles


There was no incident that led to this happening. It seemed to begin for no reason. Whenever I fill my gas tank, if I do not stop the pump before the tank is full, it overflows. This happens any time I fill the tank full. A significant amount of gasoline spills when this happens. Dodge issued a recall for this exact problem on 26,000 other 2005 Dodge Durangos, but refuses to include my vehicle in this recall #05V-034. I have no repaired the problem.

- Oak Park, IL, USA

problem #80

Dec 162009


  • 73,000 miles
Gasoline gushes out of gas tank upon refueling. Dodge Durango 2005. This occurs every time the vehicle is refueled. Gas covers the rear quarter panel and under surfaces of the vehicle as well as the gas station ground and equipment (and anyone standing near the refueling area). Chrysler refuses to include my vehicle in the recall to pay for the repair.

- Centerville, OH, USA

problem #79

Dec 102009


  • 72,000 miles
Vehicle gas tank overflows when gas is pumped until gas pump autostops. A large amount of fuel spills out in 1-5 seconds after. I have had this happen over two years now. Dealer seems to not want to fix. Recalls are conveniently not for the vehicle in question. Seems small amount of VIN qualify.

- Summitville, NY, USA

problem #78

Dec 152009


  • 89,742 miles


My 2005 Dodge Durango's tank overflows when refueling. I have contacted Dodge and am waiting on a response. This is very unsafe and I know their is recall but my VIN doesn't seem to be included.

- Littleton, CO, USA

problem #77

Nov 152009


  • 75,000 miles
Gasoline shoots out the filler neck and does not shut off automatic fuel pumps. This happens all the time unless I manually fill the tank at a very slow rate for the last few gallons. Gas spills on whoever is filling car, soaking clothing with gas and can spray in attendants face due to the height of the filler neck.

- Springfield, VA, USA

problem #76

Dec 012009


  • 59,000 miles
2005 Dodge Durango. When filling the gas tank with fuel, after the pump nozzle clicks off, the gas shoots back out of the filler neck soaking the ground and the side of the vehicle. There is a recall notice on this problem but not on the VIN # of vehicle I have.

- Indianapolis, IN, USA

problem #75

Dec 012009


  • miles
After allowing gas to fill vehicle completely, the gas nozzle stops pumping. Once I remove the gas nozzle, gas spits out of the fuel filler neck all over the vehicle and myself. This condition has occurred three times.

- Ff, ME, USA

problem #74

Nov 012009


  • 75,000 miles


Every time Durango is filled, gasoline pours out of the spout.

- Plymouth, OH, USA

problem #73

Oct 042009


  • 52,000 miles
Fuel spits back from filler neck when filling the tank. The fuel spit back and spillage is occurring at the last portion of the fill about five seconds after the nozzle kicks off.

- Knox, IN, USA

problem #72

Nov 122009


  • 28,740 miles
When filling vehicle with fuel, gas spews out all over car ground and people, creating a fire hazard at a very bad time.

- Fairhope, AL, USA

problem #71

Jan 062009


  • 57,000 miles
2005 Dodge Durango: When fueling the vehicle to full the vehicle spits gas back at you and this isn't a small amount either. This occurs mostly when fueling the vehicle to full. This has happened since we purchased the vehicle in December 2008. There is a recall number: 09V003000 and 05V034000; Chrysler claims my vehicle had the recalled performed, but I think they never fixed the problem.

- Erie, PA, USA

problem #70

Jan 132009


  • miles
Bought a 2005 Dodge Durango and checking recalls found that the problem I have with refuel overfilling was recalled. I contacted the Dodge dealership and was told my vehicle was not part of the recall. However I could change it for a charge. Every single time I fill up, I must watch and stop it before it is full or gas spurts out all over the area. This is definitely a fire hazard. I feel I should not have to pay for a problem that is being recalled.

- Springfield, MO, USA

problem #69

May 012009


  • 135,000 miles
Related to NHTSA recall campaign 09V003000, NHTSA RQ08005... my Dodge Durango - exactly same problem as described yet apparently not included in the recall. Internet search leads me to believe that several hundreds of other Durango owners have the same complaint. This has been an on-going problem over the last several months.

- Olathe, KS, USA

problem #68

Jun 022009


  • miles
This is regarding the latest safety recall notice H45 to my 2005 Dodge Durango SUV to the fuel tank inlet check valve. Since receiving this notice I have taken my car to Dodge dealer in mount airy, Maryland, a total of six times, which does not include visits to order parts and return when the part was received, approximately twelve time, I've been to this dealer. I have been very patient trying to work with Dodge, but I am losing patience, as well as any confidence in Chrysler statement ┐we┐re sorry for any inconvenience, but we are sincerely concerned about your safety┐ as stated in their notice. Each time they have worked on my car, and I fill the tank, it continues to spew gas all over me, my car, the ground, until one day given the situation, gas fumes igniting and starting a critical mishap. This is a dangerous situation and Chrysler refuses to address, on my behalf. After my third visit, I attempted to contact Chrysler at 800-853-1403, with my frustrations, and was told there was nothing they could do, and I needed to work with my dealer in mt. Airy to resolve the problem. This latest visit, October 19, 2009, where they supposedly replaced the entire tank, has left me with additional problems. The engine light stays on if fuel is below a quarter of a tank (which has never occurred before) and the odometer statement (where the numbers are) reads ┐gascap┐, even though I replace the gas cap no differently than I have for the past five years. I am very concerned about my safety as well as anyone that happens to be around me at the time of fill-up. Please advise me on anything that I can do at this point. I am speaking with an attorney, but don┐T feel that I should have to go this route. Your prompt reply is requested.

- Montgomery Village, MD, USA

problem #67

Sep 292009


  • 61,982 miles
Fuel spills out of filler neck every time I try to fuel up no matter what station or how slowly I try to fill. I get gasoline all over my vehicle, myself, and the ground. Dodge dealer told me it needs a fuel tank replaced at $750. I find a recall on this exact problem for 2005 Durangos, but they tell me it doesn't apply to mine. Same problem, same vehicle - are they yanking my chain?

- Ada, MN, USA

problem #66

Jul 012007


  • 24,000 miles
Chrysler has recalled 2005 Durango's made during a certain time for fuel component failures. (recall id # 09V003000) even though I did not receive a recall notice my vehicle is experiencing the same problem and was diagnosed with the same problem. However, Chrysler states that my problem is a result of component failure and they will not assist in any way in correcting the problem. The dealer will not assist me except to offer me a 20% discount on parts and labor. My son-in-law's 2005 Dodge truck also has the same problem as well as a 2007 Chrysler aspen purchased by a friend of mine. I believe this problem is way more wide spread than Chrysler is willing to admit. The problem is that when I auto fill my gas tank, when the auto shut off kicks in, gas gushes out of the tank, runs down the car and puddles on the ground. I have taken a video of this and will be posting it to youtube. If you would like a copy of the video, please contact me. This problem started roughly 2 years after I purchased the vehicle.

- Hazelwood, MO, USA

problem #65

Jul 202009


  • 95,000 miles
Fuel sprays out of filler neck when gas tank is full when fueling. Approximately 1/4 gallon.

- Tampa, FL, USA

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