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 21 of 23)

« Read the previous 20 complaints

problem #44

Jan 032009


  • 60,000 miles


Gas over flows all over me and ground when filling.

- New York, NY, USA

problem #43

Jan 152008


  • 40,000 miles
Fuel tank overflows and does not shut gas pump off when the tank is full. Everytime we fill the gas tank up, gas spews out violently all over the ground and onto the person fueling the vehicle. Seems pretty dangerous to me. Gas tank recall is partially in effect for certain VIN numbers but not all.

- Killeen, TX, USA

problem #42

Jan 152009


  • 60,000 miles
Whenever I fill up the gas tank the gas will come spewing out after it fills up. The first time it happened it got all over my clothes, shoes and side of the car. Thought it was a fluke with the station, but it happens everywhere I go. Happens everytime I fill up. Took it to a dealer because I heard about a recall but was told mine was not covered under the recall and would cost nearly 800 dollars to fix. I don't think so. This kind of problem should not happen. Phoned "customer service" at Dodge/Chrysler and was also given the same story about it not being in the recall. This is unacceptable.

- Milwaukee, WI, USA

problem #41

Jan 102009


  • 40,000 miles


When filling up gas tank fuel backflows out, splashing on my face and clothes. This problem occurs every time you try to fill the tank full. I have not yet fixed the problem was told by the dealership that it was a inlet check valve/ fuel tank assembly. The cost of the repairs is around $1000. I feel this should be covered by Chrysler!!!!

- Loves Park, IL, USA

problem #40

Jan 052009


  • 37,978 miles
Gas gushes out of the fill nozzle of my 2005 Dodge Durango ltd spraying the vehicle, ground, gas pump and myself with gasoline. I bought this vehicle used, Jan. 3, 2009, and this has occurred everytime that I fill up with gas, no matter how slowly the delivery rate of the pump. I contacted Dodge customer service and was told that since the recall was performed in December of 2004 and my vehicle is not covered by any subsequent incidents and were not interested in any environmental or safety issues that I was having.

- Greenwood, IN, USA

problem #39

Jan 012007


  • 30,000 miles
My fuel tank overfills everytime I fill it up at the gas station. This is no matter what station or type of pump. I have been told that my particular vehicle is not part of the recall. However I have the exact same problem as the recall.

- Fremont, CA, USA

problem #38

Mar 162009


  • 85,000 miles


I have a 2005 Dodge Durango. I recently took to a certified Chrysler dealership as I was having problems with the gas not shutting off when pumping. Fuel spills everywhere, all over the vehicle and on the ground next to the pumps. As this is a safety hazard, as well as fire safety, the dealer recommended I get the gas tank replaced. They report never having this problem with Durangos. I went home and researched this problem and found a recall for 2005 Dodge Durangos and found a recall for the exact same problem I am having. The recall is for vehicles manufactured from 10/13/2004-11/30/2004. My vehicle was manufactured on 12/1/2004, one day after the cut off for the recall. I called the company and they offered no assistance. This is an extremely dangerous situation as a spark could ignite the fuel spilled on the vehicle and the ground, and they refused to include my vehicle in the recall.

- Harlan, IA, USA

problem #37

Feb 012009


  • 36,000 miles
I own a 2005 Dodge Durango. Fuel was overflowing on the driver's side of the vehicle. As he fills his tank with gas, fuel rushes to the top and spills onto the vehicle. The dealer stated that the failure was not covered under the warranty.

- Jackson, NJ, USA

problem #36

Mar 152009


  • 50 miles
The gas filler pipe automatic shutoff has never worked properly on my 2005 Dodge Durango since it was new. When the fuel tank is full, the gas pump shuts off, but the fuel washes back out of the tank and onto the ground. The dealer claimed it was fixed in a recall prior to my purchase in 2005 according to their "computer records". obviously, from my experience in filling the tank, the "recall fix" did not work--or, worse, the dealer did not do the fix as they claimed. Spilling gasoline is dangerous--Dodge has a responsibility to make this repair work, even if it takes another recall.

- Anchorage, AK, USA

problem #35

Mar 012009


  • 78,000 miles
Gas overflow problem when filling up 2005 Dodge Durango limited. If I try to fill up my gas tank, I get splattered with gasoline, there was a recall for this problem relating to 2005 Dodge Durango, but my VIN does not match the recall.

- Omaha, NE, USA

problem #34

Jan 092009


  • 90,000 miles


The contact owns a 2005 Dodge Durango. The contact stated that fuel was overflowing on the driver's side of the vehicle. As he fills his tank with gas, fuel rushes to the top and spills onto the vehicle. The dealer stated that the failure was not covered under the warranty. The VIN was unknown. The failure mileage was 90,000.

- Aurora, CO, USA

problem #33

Jul 172008


  • 47,000 miles
The contact owns a 2005 Dodge Durango. The contact stated that the shut off valve in her fuel tank did not function correctly. She noticed the issue on three different occasions. When placing fuel into the vehicle and using the automatic device that supports the pump handle, gasoline would spill out and splash back because the valve would not shut off. The contact felt that this was a safety hazard. She took the vehicle to the dealer and referenced NHTSA campaign id numbers 09V003000 and 05V034000. The dealer stated that they would check after the oil change. After the oil change, the dealer stated that the fuel tank needed to be replaced, but it was not covered under warranty. The manufacturer has not been notified. The current mileage was 56,957 and failure mileage was approximately 47,000.

- Wylie, TX, USA

problem #32

Mar 032009


  • 25,000 miles
Our 2005 Dodge Durango gas talk overflows when filling. After researching on the issue I discovered there is a recall on models made the month prior to ours. After contacting the local service center, I was told to call the Dodge Corp. Only to have them tell me that it was not covered and there was nothing they could help me with. This is an issue that on every fillup covers the side of the vehicle and the ground with up to quart, possible more of gasoline. I did attempt to call the company another time to correct this hoping to reach another individual that might help. I was allowed to talk with a floor supervisor who once again assured me that since my vehicle was not included in the recall there was nothing they could do.

- Portsmouth, VA, USA

problem #31

Jun 162008


  • 37,000 miles
At around 38000 miles we started having issues with the gas spilling out of the filler tube of our 2005 Dodge Durango when the take gets near full when refueling. At first we thought it was that particular pump, but we have had the same issue at several different gas stations. There is a recall for what seems to be the same issue, but according to the Dodge web site, our 2005 Durango is not part of the recall. The dealer wants around $700 to replace the entire fuel tank. This is an extreme hazard as gas spills all over the ground and me when refueling. This is a well known issue and Dodge should be held accountable for this problem before someone is seriously injured. Please help!

- Thornton, CO, USA

problem #30

Feb 282009


  • 40,000 miles
My 2005 Dodge Durango spill gas whenever it near the end of filling creating a major fire hazard also now when ever I am coming to a stop of a slow down the vehicle stalls which kills the power steering and brakes. Totally unsafe and when you call Chrysler they say there is no problem. I am not going to pay for repairs that are clearly recall items. The web is littered with the same complaints and no one cares.

- Waterford, WI, USA

problem #29

Dec 042008


  • 49,000 miles
When filling up at any gas station, the pump will not automatically shut off and gasoline shoots out of the filler neck. A significant amount shoots out under pressure. This occurs every time that I fill up for approximately the last ten fill ups. There are two recall campaigns regarding this exact issue, yet Chrysler denies my claim on the basis that my VIN is not included in either campaign. I spoke to the NHTSA Office Of Defects Investigation today, and they recommended contacting the state's attorney general and the federal trade commission. Presently there are over 40 other outstanding complaints with the NHTSA regarding this exact issue. It appears that Chrysler is shirking its responsibility to repair this very dangerous safety issue. By the way, it is Chrysler alone that determines the applicable VIN numbers.

- North Franklin, CT, USA

problem #28

Feb 152009


  • 0 miles
Fuel tank inlet check valve is bad improper operation and fuel spit back during refueling.

- Obetz, OH, USA

problem #27

Nov 012008


  • 69,000 miles
The contact owns a 2005 Dodge Durango. When the gas tank was filled, the contact noticed that fuel would spill back out. The vehicle was taken to the dealer and they replaced a few parts; however, the contact does not remember which ones specifically. The failure was not corrected and the repair caused the vehicle to stall. The vehicle was taken back to the dealer. The dealer stated that the fuel tank needed to be replaced. The manufacturer stated that the VIN was not included in NHTSA campaign id number 05V034000 (fuel system, gasoline: Storage: Tank assembly: Filler pipe and cap). The failure and current mileages were 69,000.

- El Paso , TX, USA

problem #26

Jan 012009


  • 45,000 miles
When I fill of the gas tank it overflows after shut off. Has happened about 7 times. On January 26, 2009 Dodge filed a notice of defect on this problem but the company and the dealers say my car is not included in the recall.

- Broomfield, CO, USA

problem #25

Jan 102009


  • 90,000 miles
Fuel spillage regular occurrence. The tank says I am on nearly on empty, I go to the station and "fill up" the problem comes in when I get close to the end. Vent seems to prevent fuel tank to be filled and it spills all over side of vehicle. It sounds a rushing noise pump nozzle clicks and gas goes everywhere. I have contacted the dealership and they act like they have no idea this would happen. After reading complaints online I am not alone. I am told that it probably needs a new fuel tank by the dealer, I type in my VIN and it says it is not included in recall. I am thinking the same issue that causes the check valve not to close also causes it to close or stick closed as well. I am afraid that one day the fuel that splashes back will get in my eye or cause other issues like a fire. I first thought it may be a pump issue but it has happened to me at nearly every station I have went to. I am also curious how a 26 gallon tank can never take more than 20 gallons, I realize that there is a reserve but 6 gallons? please help me and the others listed on the link I included. We can't all be crazy this is a widespread issue.

- Fargo, ND, USA

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