Here is what is being done.. They are replacing the Fuel tank and filler neck. There is a check valve in the tank that apparently went bad causing the gas burp.

New tank will be in today and will be put in this week.. Hopefully this is the fix.

 

Chrysler had that "lifetime" powertrain warranty at the time when I bought the vehicle. To use this there's a $100 deductible you have to pay. The dealer (Benoy Motors in Woodstock, IL) was able to get Chrysler to pick up the cost under this warranty. It was fixed this morning and the first trip to the pump took $60....with no shooting gas!

 

Well the tank was on back order so it did not get put in last week as was planned. So it was put in today and as they were filling it up it burpped gas out @ 1/2 full..

So now they said that a call into Tech support is being made to find out what is causing this..

My thought is This New tank has a bad Valve as well...

 

We called Chrysler, and they had us take it to a dealer for diagnosis. We're out of warranty and 2nd owners (so no lifetime powertrain), so we expected to get hosed. As expected, the gas tank and neck needs to be replaced. Total cost to me: $159

I have to say, Chrysler really stepped up on this one. They've been calling DAILY since we reported the issue, and even called while we had it at the dealer. They worked it out with the dealer while we were there, and got the part ordered.

Obviously, they are stepping up to avoid liability for safety issues, and a possible (additional) recall. Regardless, I'm happy with the outcome.

 

Epilogue: Got the repair done yesterday, and filled up last night - everything works correctly again, and the gas stayed in the tank.

I'm keeping the recept so I can get reimbursed for $159 when Chrysler expands the 2005 Durango recall through the 2008s. It's bound to happen, and I think they're trying to handle this with a band-aid approach until then.

Clearly, they know there's a problem. I was able to get the fix with a $150 lifetime powertrain warranty deductable, even though I'm the 2nd owner and don't have the lifetime warranty!

 

We have a 2007 Dodge Durango and for the past 3-4 months we have been having the very same problem. Just as like a few others I have read on here the pump stops automatically but there is still the overfill before we even get the opportunity to top off. This started just after the warranty was up as well.

 

THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-001-09, DATED
APRIL 15, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A
COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT
REVISIONS.
SUBJECT:
Hard To Fill With Fuel Or Fuel Nozzle Shuts Off Repeatedly
MODELS:
2004 -2008 (CS) Pacifica
2009 (DS) Ram Truck (1500)
2007 - 2009 (DH) Ram Truck (1500/2500 Pick Up)
2004 - 2009 (DR) Ram Truck (1500 / 2500 Pick Up)
2005 - 2009 (HB) Durango
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
GROUP: Fuel
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
Markets)
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.
DISCUSSION:
Customer may report that the vehicle is hard to fill with fuel or that the fuel pump 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.
DIAGNOSIS:
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.
POLICY:
Information Only

 

You're not supposed to top off. I grew up doing this as well -- for several years. However, a few years ago I finally listened to the manufacturer and gas station, and I never top off anymore. Now, I could see this being an issue of the pump prematurely shuts off.

 

There's a huge thread on this issue over on dodgeforum. Many people are having the problem with their Durangos.

 

Topping off or not, gas should not shoot out of the tank. The check valve inside the tank was stuck open in my situation, the tank & filler neck were replaced. That was over 40k miles ago - not a problem since.