Wrangler TJ Gas Overflow Fix
- Thread starter Chris
- Start date
I've had my tank in and out several times during my build. The big risk I've seen is pinching the fuel lines between the skid and the mounting points. How did you break the fuel pump?
Removing it and replacing it were pretty simple, but the anxiety of removing it was palpable. I really thought I'd break something while doing so.
We weren't planning on dropping it but he had clearance issues trying to get the lower track bar mounting bolt out so next thing I know he'd unbolted half of it and was asking me for someone to rest it on. So I slid one of the rear tires under there and then I told him about me needing to do this repair while it was down so we fully disconnected it and slid it out on the tire. When we went to reattach it we were having issues getting it up in place because it wasn't on a jack or anything (and it wasn't empty so it wasn't super light) and at some point we overextended the fuel line, which was reconnected at this point, and snapped off the plastic nipple where the fuel line connects to the fuel pump.
(After replacing the fuel pump we got it off the tire and onto a jack before reconnecting everything and trying to remount it.)
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I have a 2001 Jeep TJ and it uses the ball same as the other early models. My Jeep has the slow fueling issue where the gas nozzle clicks off repeatedly. Is the only fix for my Jeep to replace the tank with a 05 to 06 tank or do I have an issue with the evaporator system? It took me 30 minutes to fill my Jeep up with 3 gallons of fuel. 
I posted this diagram of the fuel vent system that I marked up from the 2001 FSM in another thread a couple years ago:I have a 2001 Jeep TJ and it uses the ball same as the other early models. My Jeep has the slow fueling issue where the gas nozzle clicks off repeatedly. Is the only fix for my Jeep to replace the tank with a 05 to 06 tank or do I have an issue with the evaporator system? It took me 30 minutes to fill my Jeep up with 3 gallons of fuel.
The blue path is the path fuel vapors displaced by the fuel entering the tank take during filling. The items to check are items 4, 5, 6, and 7. Any one of those, if faulty, can cause a slow-fill situation.
To expound on my last post, the way I'd diagnose your problem is to start disconnecting things from the system in numerical order - 4, then 5, then 6, then 7 - each time filling the tank. When the problem goes away and you can fill up again, you've found the faulty component that needs replacement. The FSM and Factory Parts Manual, found on the TJ Resources forum, can help you locate each of those items, and their part numbers.
Never assume...I had already dropped my tank thinking that all the fuel tanks were the same only to find out that they are very different
My jeep also developed a long crank which actually helped me to find the root of all my issues. The fuel pressure regulator. I decided since I was going to have to drop my tank again 
that I might as well do the whole assembly which included a new regulator. This solved both issues.
that I might as well do the whole assembly which included a new regulator. This solved both issues.I’ve now read all 30 pages of this thread… every single post.
I had a couple problems that led me to replace the fuel pump: long crank on startup, randomly losing power, and a slightly rough idol. I also couldn’t get the gas pump to stay on, so I figured I would handle the inlet check valve when I had the tank dropped. I shaved down the little nubs and got the check valve moving super smoothly with no effort.
I got everything back together and went to the gas station today, no change it’s still will not fill properly. I actually went to two different stations. Spent about 10 minutes at each and got a total of about half a tank in. I’ve never had a problem with it overfilling other than the one time I had to put the nozzle in upside down to get it to fill.
Is there something else in the system that will cause the tank not to fill?
I had a couple problems that led me to replace the fuel pump: long crank on startup, randomly losing power, and a slightly rough idol. I also couldn’t get the gas pump to stay on, so I figured I would handle the inlet check valve when I had the tank dropped. I shaved down the little nubs and got the check valve moving super smoothly with no effort.
I got everything back together and went to the gas station today, no change it’s still will not fill properly. I actually went to two different stations. Spent about 10 minutes at each and got a total of about half a tank in. I’ve never had a problem with it overfilling other than the one time I had to put the nozzle in upside down to get it to fill.
Is there something else in the system that will cause the tank not to fill?
Not that I know of. But an update from today, I found a used tank for $100, swapped the tank out and the issue is gone. I can now fill it without having to hold the nozzle… glorious. It wasn’t the fill neck or the evap system as both of those remained. I am fairly certain it was the check valve on the passenger side.
Side note, there is a massive difference in the amount of fuel that is released from the line with a new pump and working check valve.
Mine burbs gas half the time. It depends on the pump and how many cars are filling. I've learned about how much to put in depending on the guage and slow the nozzle as it gets close.
I will probably fix it, but have considered replacing the tank with a bigger one.
I will probably fix it, but have considered replacing the tank with a bigger one.
Is this a typo? The check valve is on the drivers side.
But, glad you got it working. That’s the most important thing
This replacement GM filler hose fixed my 06 LJR fuel overflow issue perfectly! The part is available on Rock Auto.
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Did you keep the flapper?
It's a good option and I'm glad the internet found this solution - I too ran it for a while.
It may fix the problem but know that the sanding solution is the best long-term solution next time you need (or have the boredom desire) to drop the tank.
Do you have a link? How does the GM filler hose differ from the stock jeep hose?
It differs that it fixes the issue sometimes but eventually you'll want to fix the actual problem in the tank and then remove the GM hose, or at least that's how it worked when I did it.
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