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hollonator 08-19-2013 12:43 PM

Fuel nozzle shutting off repeatedly at the pump
I had an issue with the fuel tank on my 2007 Dodge Ram 1500 not wanting to take on fuel, it took over 30-45 minutes to fill up from empty every time...and I put up with it for a year! Well I finally fixed it using the guidance below. If anyone else is having this issue, hopefully you will also find it helpful.


Hard To Fill With Fuel Or Fuel Nozzle Shuts Off Repeatedly

2004 -2008 (CS) Pacifica
2009 (DS) [COLOR=blue ! important][COLOR=blue ! important]Ram [COLOR=blue ! important]Truck[/COLOR][/COLOR][/COLOR] (1500)
2007 - 2009 (DH) Ram Truck (1500/2500 Pick Up)
2004 - 2009 (DR) Ram Truck (1500 / 2500 Pick Up)
2005 - 2009 (HB) [COLOR=blue ! important][COLOR=blue ! important]Durango[/COLOR][/COLOR]
2007 - 2009 (HG) Aspen
2005 - 2009 (ND) Dakota
2009 (JC) Journey
2007 - 2009 (JK) Wrangler
2007 - 2009 (J1) Sebring (China CKD)
2007 - 2009 (JS) Sebring/Sebring Convertible/Avenger
2006 - 2009 (K1) Cherokee (CKD)
2007 - 2009 (KA) Nitro
2008 - 2009 (KK) Liberty
2008 - 2009 (KK) Cherokee (International Markets)
2005 - 2007 (KJ) Liberty
2005 - 2007 (KJ) Cherokee (International Markets)
2005 - 2009 (LE) 300C/300C Touring (International Markets)
2005 - 2009 (LX) 300/Magnum/Charger
2007 (L2) 300 (China)
2008 - 2009 (LC) Challenger
2004 - 2009 (PT) Chrysler PT Cruiser

NUMBER: 14-001-09 REV. A
DATE: September 1, 2009
2007 (R2) Caravan/Voyager (CKD)
2005 - 2007 (RG) Chrysler Voyager (International Markets)
2003 - 2007 (RS) Town & Country/Caravan/Voyager
2008 - 2009 (RT) Town & Country/Grand Caravan
2008 - 2009 (RT) Town & Country/Grand Voyager (International
2005 - 2006 (TJ) Wrangler
2005 - 2009 (WH) Grand Cherokee (International Markets)
2005 - 2009 (WK) Grand Cherokee
2006 - 2009 (XH) Commander (International Markets)
2006 - 2009 (XK) Commander

NOTE: This bulletin applies to all vehicles equipped with a gasoline engine.

Customer may report that the vehicle is hard to fill with fuel or that the [COLOR=blue ! important][COLOR=blue ! important]fuel [COLOR=blue ! important]pump[/COLOR][/COLOR][/COLOR] nozzle
shuts off repeatedly while trying to fill vehicle.
This customer complaint can occur due to a number of different causes. The fuel tank is
the least likely cause of this condition. The following Diagnostic procedure can be used to
diagnose the issues.

1. Is the vehicle a LX/LE/LC/L2?
a. Yes >> proceed to Step #2
b. No >> proceed to Step #4
2. Idle the vehicle 60 to 90 seconds upon stopping.
3. Does tank refill properly?
a. No >> proceed to Step #4
b. Yes >> Inform the customer to idle the vehicle for 60 to 90 seconds upon stopping if
vehicle was driven aggressively. This is due to the fact that on the LX/LE/LC/L2 the
fuel tank is a unique saddle tank design and needs 30 to 60 seconds while the
engine is running to level the fuel in both half's of the fuel tank. Allowing the vehicle
to idle for this amount of time will let the fuel pump transfer fuel to the left side tank,
opening the control valve and allowing normal fuel filling.
4. Disconnect the vapor recirculation tube at the fuel tank.
5. Attempt to refill fuel tank.
6. Does tank refill properly?
a. Yes >> Proceed to Step #7
b. No>> Proceed to Step #11.
7. Reconnect the vapor recirculation tube at the fuel tank.
8. Disconnect the other end of the vapor recirculation tube at the fuel filler tube.
9. Attempt to refill fuel tank.
10. Does tank refill properly?
a. Yes >> Replace fuel filler tube.
b. No >> Replace the vapor recirculation tube.
11. Disconnect the control valve to EVAP canister tube at the fuel tank.
14-001-09 REV. A -2-
12. Reconnect the vapor recirculation tube at the fuel tank.
13. Does tank refill properly?
a. No >> Replace Fuel Tank.
b. Yes >> Proceed to Step #14.
14. Reconnect the control valve to EVAP canister tube at the fuel tank.
15. Disconnect the control valve to EVAP canister tube at the EVAP canister.
16. Attempt to refill fuel tank.
17. Does tank refill properly?
a. Yes >> Blockage is in the EVAP Canister, or ESIM, or Clean air hose (ESIM vent
hose), or filter. Diagnose appropriately.
b. No >> Replace the control valve to EVAP canister tube.

Information Only
-3- 14-001-09 REV. A

seuss 11-16-2013 02:31 PM

Thanks for posting this. I am having the same issue. Went to the dealer and they replaced the EVAP canister & valve. But it's still happening. Any advice? Did Dodge cover this or did you have to pay out of pocket. Thanks for your help.

Race1Mopar 12-12-2013 05:32 PM

I have this same issue on my 2004 Ram and will need to troubleshoot it. The dealer said they know of the TSB but that doesn't extend the service contract. Said my truck is almost 10 years old so at this point it just considered a failed part. I could hear his whisper in my ear saying "good luck with that" lol

dauer53 12-16-2013 11:29 PM

I have the opposite of this issue on my 2011... it won't shut off right away and spits about a cup of gas out and down the truck.

driven2extreme 02-20-2014 10:40 PM

Had it happen (overflowing) on my 05 Durango, there was recall but didn't include my vin. and it was past the "time frame" was what my local dealer said. Called Chrysler Customer Service 800 #. Took some bitching and moaning but fuel tank was replaced free of charge to me. Havent had any issues on my 10 Ram yet, hopefully wont, It was a pain not being able to fill it. Good Luck

ghostryder63 10-13-2014 06:46 PM

I have had both the sloshing out problem and within the last month it is hard to fill my 08 ram. Got a letter from Chrysler saying they had extended the warranty for this issue. Took my truck in last week and they replaced the filler tube and the check valve. I went to fill and the same thing but so sloshing out. Took it back today and they ordered the parts again to replace in case they got defective parts. They tell me that if this does not fix the problem, it could be the fuel pump going bad. Sound reasonable to any of you?

bd0202 01-06-2015 11:54 PM

I am having this trouble currently, but oddly enough it only seems to be happening when it's cold out (50 deg or lower). In warmer weather it's been taking fuel just fine. That originally made me think it wasn't a vent problem but a temperature problem. The fuel intake line is non-insulated metal then goes into a rubber hose just before linking with the tank - potentially could be warmer fuel reacting to cold metal, which would be an easy fix with some pipe insulation. But I didn't do it yet...

I saw this TSB on AllData, but I'm going to follow this more updated version and see how it goes. I really hope I don't have to drop the tank or take it to a dealer. *Crosses Fingers*

I've noticed in my research so far that the fuel pump and everything else seems to be one complex assembly, and located right above the tank. Even the filter is there! That's a pretty crappy design if you ask me, so I'm really hoping that's not the case. If I drop that tank, I'm going to replace EVERYTHING!

bd0202 04-01-2015 03:33 PM

I've been hesitant to post this reply because I'm still afraid it'll come back. But for the time being, I think I stumbled across a "fix" by accident. I would say this could probably fix some, but not all, of the trucks experiencing this issue.

Anyway, I went to the coast for my birthday two months ago. It was rainy, nasty, and cold (typical in February but I still love it). The beach driving conditions were interesting - sand was packed tight and wet so no one was getting stuck, but pools of water were sitting everywhere and there were a lot of bumps, ripples, and waves of pack sand along the road. When I left I went to the service station to fill up and the issue was GONE. It took fuel fine.

I continued to fill up weekly as I do back on my routine at home, and to this day I still haven't had anymore trouble. I think I unintentionally knocked whatever it was loose driving in the rough conditions down there.

My thinking is that either some part of the assembly broke loose inside and was blocking ventilation, or someone might have tried to siphon gas from my truck and lost some foreign object in the process. Either way, I won't know for sure until I drop the tank - but as long as it's working I'm not going to be doing that.

So go out and try some rough driving if you can, it may just work for you, too! :smiley_thumbs_up:

idaho181 11-07-2015 08:53 PM

My first two fill ups after leaving the dealership did the cut off & barf routine. I'm now on three fill ups and it has stopped doing this. Beats me!


RansRAM 11-07-2015 09:39 PM

WOW, 35-45 minutes to fill up. I can only imagine how that would feel up here in the dead of winter. :doh:

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