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 16 of 17)

« Read the previous 20 complaints

problem #37

Feb 202010


  • 74,839 miles


Vehicle doesn't automatically shut off gas pump when refueling, causing the fuel to overflow and spill.

- Saugus, CA, USA

problem #36

Feb 172010


  • miles
Every time when filling gas it overflows out of my Jeep.

- Amherst, NY, USA

problem #35

Feb 162010


  • 26,500 miles
Fuel tank overflow problem. Every time I fill up a significant amount of fuel spills from the tank.

- O'fallon, MO, USA

problem #34

Feb 162010


  • 60,000 miles


Fuel overflows when refueling.

- Houston, TX, USA

problem #33

Feb 122010


  • 70,000 miles
Filling up my gas tank, it overflows the pump everytime. I as of yet have done nothing. Sometimes when approaching full tank, I will try to reduce the flow of the pump.

- Chicago, IL, USA

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problem #32

Feb 182010


  • 0 miles
1. fuel overflows when filling vehicle with fuel at gas pump 2. everytime I fill my vehicle, it spills gasoline on me and the ground at the station. 3. none available to my knowledge.

- Cocoa , FL, USA

problem #31

Feb 082010


  • 40,000 miles


Every time I get gas in my 2005 Jeep Wrangler it overfills by the time the pump shuts off. This leads to gas coming out the fuel filler. This can lead to unsafe conditions as gas is flammable. Also it will eventually mark the paint.

- New Florence, PA, USA

problem #30

Jan 072010


  • 43,696 miles
While at the pump the gas nozzle kicks off and then about a pint of fuel dumps out of the vehicle. This is widely known on the Wrangler, with the oldest vehicle I've heard this happening to is from '98 and newest a 2009. Jeep redesigned the Wrangler in '97 including the fuel system, so I'm sure there's a defect in the fuel system. Chrysler's answer is to just replace the tank which will eventually fail again. This can be a serious hazard and could easily cause a fire. One guy said it dumped fuel on his boots while another guy had fuel spray him from head to toe. Here is a few links from one forum showing the issue including a few videos (fast forward to the last 20 seconds) and many complaints about this issue. www.jeepforum.com/forum/F9/have-fuel-spill-problems-like-many-us-submit-complaint-force-recall-974337/ www.jeepforum.com/forum/F9/gas-spilling-over-when-filling-872096/.

- Lakewood, WA, USA

problem #29

Jul 012009


  • 35,000 miles
When filling my 2005 Jeep Wrangler with gas it overflows and sprays gasoline out the fill hole instead of the fuel pump shutting off as it should. This happens everytime I fuel up regardless of what gas station/pump I use. This seems like a huge fire hazard as well as an environmental issue.

- Seaton, IL, USA

problem #28

May 012009


  • 50,000 miles
2005 Jeep rubicon 75,000 miles swb. Everytime I fill up, gas comes up the filler neck and gushes all over my Jeep and whoever is filling it ( I live in NJ) it has been happening for almost a year I can not afford to change my tank I just never fill up all the way. It is a real inconvenience when I go on long trips. I hope Jeep will address this issue it is not normal wear and tear.

- Montvale , NJ, USA

problem #27

Feb 182010


  • 12,000 miles


I have a 2005 Jeep Wrangler X model. Every time I fill it with gas it will overflow. Does not matter which gas station I use.

- Chesapeake, VA, USA

problem #26

Dec 282009

Wrangler 6-cyl

  • 57,773 miles
When I fill up with gas it spills out everytime. Sometimes it has so much pressure built up it sprays gas all over the place.

- Kansas City, MO, USA

problem #25

May 012005

Wrangler 4WD 6-cyl

  • 30,000 miles
My 2005 Jeep Wrangler spews gas out the filler every time I fill it up. This started around 30,000 miles and has been doing it since. Fortunately this has not caused any serious problem yet but spilling gas every time I fill up is not only a waste but a hazard to the environment and a dangerous situation. This is not a lone incident, many reports of this exact issue have come up on internet forums and other Jeep owners of similar years who I know. People are even posting videos of it on U tube! from my limited research this appears to be a faulty valve in the gas tank, which dealerships are not covering under warranty.

- Norfolk, VA, USA

problem #24

Feb 132010


  • 86,296 miles
While filling up my 2005 Jeep Wrangler tj it regularly overflows and spills gas all over the side of the vehicle and on me and my clothes.

- Frisco, TX, USA

problem #23

Jan 262010


  • 49,450 miles
05 Jeep Wrangler, when filling gas tank, with pump on auto fill, it over flows onto the ground.

- Parrish, FL, USA

problem #22

Jan 222010


  • 18,000 miles
I own a 2005 Jeep Wrangler lwb, recently, every time I fill up with fuel, gas shoots out of the fuel filler. This defect is well documented on the Jeep website forums. It seems Chrysler is replacing some fuel tanks, as they are attributed to the rollover valve, built into the tank. But, as I see it, this is a design flaw, as the tanks they are replacing, will in time, do the same thing. Your timely investigation of this matter, is of utmost importance. The violence of some of the spills I have witnessed, deserve immediate action.

- Sterling Hts., MI, USA

problem #21

Jan 192010


  • 38,010 miles
Hello, our 2005 Jeep Wrangler has an issue with gas spilling out of the gas tank whenever it is filled up at the gas station. A significant volume of gasoline sprays outward onto the driver, and down the side of the vehicle, which I believe may be a safety concern. It seems this is a design flaw and is quite common, as I have even seen video documentation on web sites such as "youtube."

- San Antonio, TX, USA

problem #20

Dec 092009


  • 46,850 miles
When filling up my 2005 Jeep Wrangler unlimited. It will click the hose off letting you know that it is full then you get a back splash of gas all over the side of the Jeep and goes on the ground. It happens ever time I fill the Jeep.

- Eaton, OH, USA

problem #19

Jan 052010


  • 50,000 miles
I have on multiple occasions had fuel overflow (actually more shoot out) while fueling my 2005 Jeep Wrangler rubicon. It occurs as the fuel is nearing full. This has happened at many different fueling locations and I always pump on the lowest setting. I have even been sprayed manually filling the tank. After reading the tj technical forum on jeepforum.com this seems to be an extremely common problem. The approximate incident date is the last time this happened.

- Pierce, CO, USA

problem #18

Dec 052009


  • 35,000 miles
1. two months ago while at the gas station filling the tank of my 2005 Jeep Wrangler X, the pump did not shutoff and fuel spilled. I thought this was a problem with the stations pump, so I decided to try a different station for my next fill-up. A week later; while filling at another station the same problem occurred. 2. in the three instances the over flow happened; I was holding the fill handle in the 6 O'clock position, the nozzle was fully inserted into the fill hole, and I had the handle fully depressed (nozzle wide open). As the tank reached full, it did not automatically shutoff, it continued filling until about a quart of gasoline spilled onto the side of my vehicle and the ground. I have contacted Chrysler's warranty department, service contracts department, goodwill team, and senior resolution team to make them aware of the defect and request them to take action. Unfortunately, I believe my calls are being simply marked to a case file and no investigatory action is being taken. I can easily see an incident such as mine leading to injury of an unknowing Chrysler owner. If any static charge is present (I.e. in clothing or the vehicle) when the overflow occurs the gas will ignite. The problem poses the greatest threat when it happens the first time, because the owner will have no warning signals of a failed part(s) and therefore will not be expecting the spill. 3. to avoid this problem from happening; I know longer fill my tank to its' full 16 gallon capacity. I have taken my vehicle to the local Jeep dealership and they have advised that I need to replace the vapor canister.

- Baton Rouge, LA, USA

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