I too am having this problem. At first I thought it was just user error as it wouldn't happen all the time.

I filed a complaint with the NTHSA.

I'm going to have to call Chrysler and see if they will fix it. Is the new TSB enough to get it fixed for free? Is calling Chrysler the best place to start or go with a dealer?

 

TSBs are only fixed for free if its under warranty, otherwise you have to pay for them.

Recalls are fixes for free in or out of warranty.

 

Here is a copy of the E01 recall.

March 2005
Dealer Service Instructions for:
Safety Recall E01
Fuel Tank Inlet Check Valve
2005 (HB) Dodge Durango
NOTE: This recall applies only to the above vehicles built through
October 12, 2004 (MDH101223).
The fuel tank inlet check valve on about 24,000 of the above vehicles may stick in
the open position. This can cause fuel to spill out of the filler tube when the
vehicle is being refueled. Fuel in the presence of an ignition source can result in a
fire.
The fuel tank inlet check valve must be tested for proper operation. Vehicles with
a sticking check valve must have the fuel tank replaced.
Models
IMPORTANT: Some of the involved vehicles may be in dealer new vehicle
inventory. Federal law requires you to stop sale and complete this recall
service on these vehicles before retail delivery. Dealers should also consider this
requirement to apply to used vehicle inventory and should perform this recall on
vehicles in for service. Involved vehicles can be determined by using the VIP
inquiry process.
Subject
Repair
Safety Recall E01 – Fuel Tank Inlet Check Valve Page 2
Dealers should attempt to minimize customer inconvenience by placing the owner
in a loaner vehicle if inspection determines that a new fuel tank is required and the
vehicle must be held overnight.
Part Number Description
CBE0E010 Fuel Tank Package
Each package contains the following components:
Quantity Description
1 Fuel Tank
1 Fuel Pump Module Seal
Due to the small number of involved vehicles expected to require fuel tank
replacement, no parts will be distributed initially. Fuel tank assemblies should be
ordered only after inspection determines that replacement is required. Very
few vehicles are expected to require fuel tank replacement.
The following Special Tools may be required to perform this recall:
! 8404 or 8404A Evaporative Emissions Leak Detector (Smoke Machine)
! 9340 Lock Ring Remover / Installer
! 9790 Probe Tool Kit consisting of:
9790-1 Probe Tool
9790-2 Canister Vent Tube Adapter
9790-3 Vent Line Plug
! CH9401* StarSCAN Tool
! CH9404* StarSCAN Vehicle Cable
* Part of CH9400 StarSCAN Diagnostic Kit.
Alternate Transportation
Parts Information
Special Tools
Safety Recall E01 – Fuel Tank Inlet Check Valve Page 3
A. Testing Inlet Check Valve Operation (Smoke Test):
NOTE: Fuel level in the tank is not
critical to perform this test.
1. Open the fill cap door and slowly
remove the gas cap.
2. Raise the vehicle on an appropriate
hoist using the proper lift points.
3. Disconnect the vent tube quick
connect located next to the filler tube
(Figure 1).
4. Using Miller Special Tool 9790-3,
plug the vent tube on the fuel tank
side of the quick connect fitting
(Figure 2).
Service Procedure
Safety Recall E01 – Fuel Tank Inlet Check Valve Page 4
5. Disconnect the carbon canister vent tube quick connect fitting from the canister.
Service Procedure (Continued)
Figure 3
Safety Recall E01 – Fuel Tank Inlet Check Valve Page 5
6. Connect the Smoke Machine
Adapter (Special Tool 9790-2) to
the canister vent tube quick connect
fitting.
7. Connect the other end of the Smoke
Machine Adapter (Special Tool
9790-2) to the black discharge hose
on the Smoke Machine (Special
Tool 8404 or 8404A).
8. Lower the vehicle.
9. Turn on the Smoke Machine
(Special Tool 8404 or 8404A) and
inject smoke into the canister vent tube, filling the fuel tank for approximately
30 seconds.
! If smoke comes out of the fuel filler tube, continue with Section “B”
Replace the Fuel Tank.
! If no smoke comes out of the fuel filler tube, continue with Step 10 of this
procedure.
10. Turn off the Smoke Machine.
11. Apply a small amount of engine oil to the
rubber plunger located on the end of the
Probe Tool (Special Tool 9790-1). This
will aid in the insertion and removal of
the tool.
12. Insert the probe tool filler tube adapter
into the filler tube opening.
The filler tube adapter is part of the probe
tool.
CAUTION: To prevent tool damage
the filler tube adapter must be installed
before inserting the probe tool.
Service Procedure (Continued)
Figure 4
Figure 5
Safety Recall E01 – Fuel Tank Inlet Check Valve Page 6
13. Insert the Probe Tool (Special Tool 9790-1) until the handle of the tool is
bottomed against the filler tube adapter (Figure 6). This will open the fuel tank
inlet check valve. A slight burst of pressure and smoke will indicate that the
inlet check valve has been opened. Keep the probe tool fully inserted for five
seconds.
NOTE: You may feel some slight resistance when inserting or removing
the tool. This is due to the probe tool making its way around the various
bends in the filler tube. This is a normal condition.
14. In an attempt to get the inlet check valve to stick in the open position, slowly
remove the probe tool from the filler tube.
15. Turn on the Smoke Machine (Special Tool 8404A) and begin injecting smoke
into the tank through the canister vent tube.
Service Procedure (Continued)
Figure 6
Safety Recall E01 – Fuel Tank Inlet Check Valve Page 7
16. Watch for smoke exiting the fuel filler
tube opening:
! If no smoke is seen coming out of the
fuel filler tube, the valve is working
properly. Repeat Steps 13 through 16
a second time to verify that the valve is
working properly. If no smoke comes
out of the fill tube opening during both
attempts, continue with Step 17 of this
procedure.
! If smoke comes out of the fuel filler
tube opening, the inlet check valve is
defective. Continue with Section B –
Replace the Fuel Tank.
17. Turn off and disconnect the Smoke Machine
(Special Tool 8404A) from the canister vent line.
18. Connect the canister vent line to the carbon canister.
19. Remove the Vent Tube Plug (Special Tool 9790-3) installed in the vent tube and
reconnect the vent tube quick connect.
20. Install the gas cap and close the fuel door.
21. Return the vehicle to the customer.
Service Procedure (Continued)
Safety Recall E01 – Fuel Tank Inlet Check Valve Page 8
B. Replace the Fuel Tank:
NOTE: Fuel tank replacement is only required if the vehicle fails the “Smoke
Test” performed in Section “A.” Very few vehicles are expected to require fuel
tank replacement.
WARNING: The fuel system is under a constant pressure (even with the
engine off). Before replacing the fuel tank, the fuel system pressure must be
released.
1. Use the following procedure to release the fuel pressure from the fuel system:
a. Remove the fuel pump relay from the Power Distribution Center (PDC). To
determine the location of the fuel pump relay, refer to the label on the
underside of the PDC cover.
b. Start and run the engine until it stalls.
c. Attempt to restart the engine until it will no longer run.
d. Turn the ignition to the “OFF” position.
e. Install the fuel pump relay back into the PDC.
NOTE: Do not turn the key to the “run” position until all repairs have
been made. Turning the key to the “RUN” position will turn on the fuel
pump and pressurize the fuel system.
CAUTION: One or more Diagnostic Trouble Codes (DTC’s) may have
been stored in the Powertrain Control Module (PCM) due to the fuel
pump relay removal. A diagnostic scan tool must be used to erase all
DTC’s.
Service Procedure (Continued)
Safety Recall E01 – Fuel Tank Inlet Check Valve Page 9
2. Drain the fuel tank using the following procedure:
a. Raise the vehicle on a hoist.
b. If equipped, remove the fuel tank skid plate.
c. Thoroughly clean the area around the fuel filler fitting and rubber hose at the
rear of the tank.
d. Loosen the clamp and disconnect the rubber fuel filler tube at the gas tank
fitting.
e. Using an approved fuel storage tanker, drain the fuel tank through the fuel
tube filler fitting on the fuel tank.
Service Procedure (Continued)
Figure 8
Safety Recall E01 – Fuel Tank Inlet Check Valve Page 10
3. Support the fuel tank with a hydraulic
transmission jack.
4. Remove the two fuel tank strap bolts and
remove both tank support straps.
5. Carefully lower the fuel tank a few inches
and disconnect the fuel pump module
electrical connector located on the top of
the tank.
6. Disconnect the fuel line quick connect at
the fuel pump module.
7. Disconnect the Natural Vacuum Leak Detection (NVLD), On-board Refueling
Vapor Recovery (ORVR), and Evaporative (EVAP) lines located at the front of
the fuel tank.
8. Disconnect the NVLD electrical connector.
9. Continue to lower the tank for removal.
10. With the help of an assistant, remove the old tank from the hydraulic jack and
set the tank on the floor.
Service Procedure (Continued)
Figure 9
Safety Recall E01 – Fuel Tank Inlet Check Valve Page 11
11. Use the following procedure to remove the
fuel pump module:
a. Note the rotational position of the
module before attempting removal. An
indexing arrow is located on the top of
the module for this purpose.
b. Position Special Tool 9340 into the
notches on the outside edge of the lock
ring (Figure 10).
c. Install a 1/2 inch drive breaker bar to
Special Tool 9340.
d. Rotate the breaker bar counter-clockwise to loosen the lock ring.
e. Remove the lock ring.
NOTE: The module will spring up slightly when the lock ring is removed.
f. Lift the fuel pump module from the fuel tank.
CAUTION: Be careful not to bend the float arm while removing the fuel
pump module.
12. Discard the old tank using an environmentally safe method.
13. Remove the new fuel tank from its packaging.
14. Install a new seal into the fuel pump module opening.
15. Position the fuel pump module into the opening in the fuel tank.
16. Position the lock ring over the top of the fuel pump module (Figure 10).
17. Rotate the module until the embossed alignment arrow points to the center
alignment mark.
NOTE: The pump module must be indexed to prevent the fuel gauge float
from contacting the side of the fuel tank. Also be sure the fuel fitting on the
top of the pump module is pointing towards the driver’s side of the vehicle.
18. Using Special Tool 9340 and a 1/2 inch breaker bar, tighten the lock ring
(clockwise) until all seven notches have engaged (Figure 10).
Service Procedure (Continued)
Figure 10
Safety Recall E01 – Fuel Tank Inlet Check Valve Page 12
19. Transfer the NVLD pump, canister and canister vent line located on the front of the
old fuel tank to the new fuel tank.
20. Transfer the heat shields from the old tank to the new tank.
21. Place the fuel tank assembly onto the hydraulic jack.
22. Carefully raise the tank until positioned near the body.
23. Connect the EVAP, ORVR and NVLD hoses and electrical connector located at
the front of the tank.
24. Connect the fuel pump module electrical connector located at the top of the tank.
25. Connect the fuel line quick-connect fitting to the pump module.
26. Connect the fuel fill tube while raising the fuel tank into position. Continue
raising the fuel tank until it is positioned snug against the floor pan.
27. Install and position both fuel tank support straps (Figure 9).
28. Install the fuel tank strap retaining bolts and tighten bolts to 30 ft. lbs. (41 N·m).
29. Position and tighten the fuel filler tube hose clamps (Figure 8).
30. Connect the fuel tank vent hose located next to the fuel fill tube (Figure 8).
31. If equipped, install the fuel tank skid plate. Tighten the bolts to 30 ft. lbs. (41 N·m).
32. Lower the vehicle and refill the fuel tank with the fuel that was removed.
33. Start the engine and check for leaks at the fuel tank and pump module area.
34. Connect the StarSCAN diagnostic tool and check all modules for Diagnostic
Trouble Codes (DTC’s).
NOTE: When the fuel pump relay was removed to release the fuel system
pressure, a Diagnostic Trouble Code (DTC) may have been set. Some DTC’s
may cause the Malfunction Indicator Lamp to illuminate. Check all modules
using “System View” from the ”Home” screen, record the DTC’s, and erase
these DTC’s prior to returning the vehicle to the customer. Erase any DTC’s
in the Powertrain Control Module only after all other modules have had their
DTC’s erased.
Service Procedure (Continued)
Safety Recall E01 – Fuel Tank Inlet Check Valve Page 13
Claims for vehicles that have been serviced must be submitted on the
DealerCONNECT Claim Entry Screen located on the Service tab. Claims
submitted will be used by DaimlerChrysler to record recall service completions
and provide dealer payments.
Use one of the following labor operation numbers and time allowances:
Labor Operation Time
Number Allowance
Test Fuel tank Inlet Check
Valve Operation
Test Fuel tank Inlet Check
Valve Operation and Replace
Fuel Tank (without skid plate)
Test Fuel tank Inlet Check
Valve Operation and Replace
Fuel Tank (with skid plate)
Add the cost of the recall parts package plus applicable dealer allowance to your claim.
NOTE: See the Warranty Administration Manual, Recall Claim Processing
Section, for complete recall claim processing instructions.
All dealers will receive a copy of this dealer recall notification letter by mail. Two
additional copies will be sent through the DCMMS. To view this notification on
DealerCONNECT, select “Global Recall System” on the Service tab, then click on
the description of this notification.
Completion Reporting and Reimbursement
Dealer Notification
Safety Recall E01 – Fuel Tank Inlet Check Valve Page 14
All involved vehicle owners known to DaimlerChrysler are being notified of the
service requirement by first class mail. They are requested to schedule appointments
for this service with their dealers. A generic copy of the owner letter is attached.
Enclosed with each owner letter is an Owner Notification postcard to allow owners
to update our records if applicable.
All involved vehicles have been entered into the DealerCONNECT Global Recall
System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed.
GRS provides involved dealers with an updated VIN list of their incomplete
vehicles. The owner’s name, address and phone number are listed if known.
Completed vehicles are removed from GRS within several days of repair claim
submission.
To use this system, click on the “Service” tab and then click on “Global Recall
System.” Your dealer’s VIN list for each recall displayed can be sorted by: those
vehicles that were unsold at recall launch, those with a phone number, city, zip
code, or VIN sequence.
Dealers must perform this repair on all unsold vehicles before retail delivery.
Dealers should also use the VIN list to follow up with all owners to schedule
appointments for this repair.
Recall VIN lists may contain confidential, restricted owner name and address information that
was obtained from the Department of Motor Vehicles of various states. Use of this information
is permitted for this recall only and is strictly prohibited from all other use.
If you have any questions or need assistance in completing this action, please
contact your Service and Parts District Manager.
Customer Services Field Operations
DaimlerChrysler Corporation
Owner Notification and Service Scheduling
Vehicle Lists, Global Recall System, VIP and Dealer Follow Up
Additional Information
SAFETY RECALL – FUEL TANK INLET CHECK VALVE
Dear: (Name)
This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.
DaimlerChrysler Corporation has decided that a defect, which relates to motor vehicle safety, exists in
some 2005 model year Dodge Durango vehicles.
The problem is... The fuel tank inlet check valve on your vehicle (VIN: xxxxxxxxxxxxxxxxx) may
stick in the open position. This can cause fuel to spill out of the filler tube when
the vehicle is being refueled. Fuel in the presence of an ignition source can
result in a fire.
What your dealer
will do...
DaimlerChrysler will repair your vehicle free of charge (parts and labor). To do
this, your dealer will test your vehicle’s inlet check valve and replace the fuel tank if
necessary. The test will take about an hour to complete and fuel tank replacement, if
required, will take another hour. However, additional time may be necessary
depending on how dealer appointments are scheduled and processed.
What you must
do to ensure your
safety...
Simply contact your dealer right away to schedule a service appointment. Ask the
dealer to hold the part for your vehicle or to order it before your appointment.
Remember to bring this letter with you to your dealer.
If you need
help...
If you have questions or concerns which your dealer is unable to resolve, please
contact DaimlerChrysler at 1-800-853-1403.
Please help us update our records, by filling out the enclosed prepaid postcard, if any of the conditions
listed on the card apply to you or your vehicle. Be sure to print the last eight (8) characters of the VIN
(VVVVVVVV) and notification code E01 on the postcard.
If you have already experienced this condition and have paid to have it repaired, you may send your
original receipts and/or other adequate proof of payment to the following address for reimbursement:
DaimlerChrysler, P.O. Box 610207, Port Huron, MI 48061-0207, Attention: Reimbursement.
If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you
may submit a written complaint to the Administrator, National Highway Traffic Safety Administration,
400 Seventh Street, S.W., Washington, DC 20590, or call the toll-free Auto Safety Hotline at
1-888-327-4236.
We're sorry for any inconvenience, but we are sincerely concerned about your safety. Thank you for your
attention to this important matter.
Customer Services Field Operations
DaimlerChrysler Corporation
Notification Code E01
Note to lessors receiving this recall: Federal regulation requires that you forward this recall notice to the lessee within 10 days.

 

Here is a copy of the H45 recall.

Dealer Service Instructions for:
Safety Recall H45
Fuel Tank Inlet Check Valve
2005 (HB) Dodge Durango
NOTE: This recall applies only to the above vehicles built from October 13, 2004
through November 30, 2004 (MDH101300 through 113023).
The fuel tank inlet check valve on about 18,900 of the above vehicles may stick in
the open position. This can cause fuel to spill out of the filler tube when the
vehicle is being refueled. Fuel in the presence of an ignition source can result in a
fire.
The fuel tank inlet check valve must be tested for proper operation. Vehicles with
a sticking check valve must have the fuel tank replaced.
Models
IMPORTANT: Some of the involved vehicles may be in dealer used vehicle
inventory. Dealers should complete this recall service on these vehicles before
retail delivery. Dealers should also perform this recall on vehicles in for service.
Involved vehicles can be determined by using the VIP inquiry process.
Subject
Repair
Safety Recall H45 – Fuel Tank Inlet Check Valve Page 2
Dealers should attempt to minimize customer inconvenience by placing the owner
in a loaner vehicle if inspection determines that a new fuel tank is required and the
vehicle must be held overnight.
Part Number Description
CBE0E010 Fuel Tank Package
Each package contains the following components:
Quantity Description
1 Fuel Tank
1 Fuel Pump Module Seal
Due to the small number of involved vehicles expected to require fuel tank
replacement, no parts will be distributed initially. Fuel tank assemblies should be
ordered only after inspection determines that replacement is required. Very
few vehicles are expected to require fuel tank replacement.
The following Special Tools may be required to perform this recall:
�� 8404 or 8404A Evaporative Emissions Leak Detector (Smoke Machine)
�� 9340 Lock Ring Remover / Installer
�� 9790 Probe Tool Kit consisting of:
9790-1 Probe Tool
9790-2 Canister Vent Tube Adapter
9790-3 Vent Line Plug
�� CH9401* StarSCAN Tool
�� CH9404* StarSCAN Vehicle Cable
* Part of CH9400 StarSCAN Diagnostic Kit.
Alternate Transportation
Parts Information
Special Tools
Safety Recall H45 – Fuel Tank Inlet Check Valve Page 3
A. Testing Inlet Check Valve Operation (Smoke Test):
NOTE: Fuel level in the tank is not
critical to perform this test.
1. Open the fill cap door and slowly
remove the gas cap.
2. Raise the vehicle on an appropriate
hoist using the proper lift points.
3. Disconnect the vent tube quick
connect located next to the filler tube
(Figure 1).
4. Using Miller Special Tool 9790-3,
plug the vent tube on the fuel tank
side of the quick connect fitting
(Figure 2).
Service Procedure
Figure 1 –Vent Tube Quick Connect
Figure 2 – Plug Vent Tube
Safety Recall H45 – Fuel Tank Inlet Check Valve Page 4
5. Disconnect the carbon canister vent tube quick connect fitting from the canister
(Figure 3).
Service Procedure (Continued)
Figure 3 – Carbon Canister Vent Tube
Safety Recall H45 – Fuel Tank Inlet Check Valve Page 5
6. Connect the Smoke Machine
Adapter (Special Tool 9790-2) to
the canister vent tube quick connect
fitting (Figure 4).
7. Connect the other end of the Smoke
Machine Adapter (Special Tool
9790-2) to the black discharge hose
on the Smoke Machine (Special
Tool 8404 or 8404A).
8. Lower the vehicle.
9. Turn on the Smoke Machine
(Special Tool 8404 or 8404A) and
inject smoke into the canister vent tube, filling the fuel tank for approximately
30 seconds.
�� If smoke comes out of the fuel filler tube, continue with Section “B”
Replace the Fuel Tank.
�� If no smoke comes out of the fuel filler tube, continue with Step 10 of this
procedure.
10. Turn off the Smoke Machine.
11. Apply a small amount of engine oil to the
rubber plunger located on the end of the
Probe Tool (Special Tool 9790-1). This
will aid in the insertion and removal of
the tool.
12. Insert the probe tool filler tube adapter
into the filler tube opening.
The filler tube adapter is part of the probe
tool.
CAUTION: To prevent tool damage
the filler tube adapter must be installed
before inserting the probe tool.
Service Procedure (Continued)
Figure 4 – Connect Smoke Machine
Figure 5 – Insert Probe
Safety Recall H45 – Fuel Tank Inlet Check Valve Page 6
13. Insert the Probe Tool (Special Tool 9790-1) until the handle of the tool is
bottomed against the filler tube adapter. This will open the fuel tank
inlet check valve. A slight burst of pressure and smoke will indicate that the
inlet check valve has been opened. Keep the probe tool fully inserted for five
seconds.
NOTE: You may feel some slight resistance when inserting or removing
the tool. This is due to the probe tool making its way around the various
bends in the filler tube. This is a normal condition.
14. In an attempt to get the inlet check valve to stick in the open position, slowly
remove the probe tool from the filler tube.
15. Turn on the Smoke Machine (Special Tool 8404A) and begin injecting smoke
into the tank through the canister vent tube.
Service Procedure (Continued)
Figure 6 – Opening the Fuel Tank Check Valve
Safety Recall H45 – Fuel Tank Inlet Check Valve Page 7
16. Watch for smoke exiting the fuel filler
tube opening:
�� If no smoke is seen coming out of the
fuel filler tube, the valve is working
properly. Repeat Steps 13 through 16
a second time to verify that the valve is
working properly. If no smoke comes
out of the fill tube opening during both
attempts, continue with Step 17 of this
procedure.
�� If smoke comes out of the fuel filler
tube opening, the inlet check valve is
defective. Continue with Section B –
Replace the Fuel Tank.
17. Turn off and disconnect the Smoke Machine
(Special Tool 8404A) from the canister vent line.
18. Connect the canister vent line to the carbon canister.
19. Remove the Vent Tube Plug (Special Tool 9790-3) installed in the vent tube and
reconnect the vent tube quick connect.
20. Install the gas cap and close the fuel door.
21. Return the vehicle to the customer.
Service Procedure (Continued)
Figure 7 – Watch for Smoke
Safety Recall H45 – Fuel Tank Inlet Check Valve Page 8
B. Replace the Fuel Tank:
NOTE: Fuel tank replacement is only required if the vehicle fails the “Smoke
Test” performed in Section “A.” Very few vehicles are expected to require fuel
tank replacement.
WARNING: The fuel system is under a constant pressure (even with the
engine off). Before replacing the fuel tank, the fuel system pressure must be
released.
1. Use the following procedure to release the fuel pressure from the fuel system:
a. Remove the fuel pump relay from the Power Distribution Center (PDC). To
determine the location of the fuel pump relay, refer to the label on the
underside of the PDC cover.
b. Start and run the engine until it stalls.
c. Attempt to restart the engine until it will no longer run.
d. Turn the ignition to the “OFF” position.
e. Install the fuel pump relay back into the PDC.
NOTE: Do not turn the key to the “run” position until all repairs have
been made. Turning the key to the “RUN” position will turn on the fuel
pump and pressurize the fuel system.
CAUTION: One or more Diagnostic Trouble Codes (DTC’s) may have
been stored in the Powertrain Control Module (PCM) due to the fuel
pump relay removal. A diagnostic scan tool must be used to erase all
DTC’s.
Service Procedure (Continued)
Safety Recall H45 – Fuel Tank Inlet Check Valve Page 9
2. Drain the fuel tank using the following procedure:
a. Raise the vehicle on a hoist.
b. If equipped, remove the fuel tank skid plate.
c. Thoroughly clean the area around the fuel filler fitting and rubber hose at the
rear of the tank.
d. Loosen the clamp and disconnect the rubber fuel filler tube at the gas tank
fitting.
e. Using an approved fuel storage tanker, drain the fuel tank through the fuel
tube filler fitting on the fuel tank.
Service Procedure (Continued)
Figure 8 – Drain Fuel Tank Through Fuel Tube Filler Fitting
Safety Recall H45 – Fuel Tank Inlet Check Valve Page 10
3. Support the fuel tank with a hydraulic
transmission jack.
4. Remove the two fuel tank strap bolts and
remove both tank support straps.
5. Carefully lower the fuel tank a few inches
and disconnect the fuel pump module
electrical connector located on the top of
the tank.
6. Disconnect the fuel line quick connect at
the fuel pump module.
7. Disconnect the Natural Vacuum Leak Detection (NVLD), On-board Refueling
Vapor Recovery (ORVR), and Evaporative (EVAP) lines located at the front of
the fuel tank.
8. Disconnect the NVLD electrical connector.
9. Continue to lower the tank for removal.
10. With the help of an assistant, remove the old tank from the hydraulic jack and
set the tank on the floor.
Service Procedure (Continued)
Figure 9 – Fuel Tank Straps
Safety Recall H45 – Fuel Tank Inlet Check Valve Page 11
11. Use the following procedure to remove the
fuel pump module:
a. Note the rotational position of the
module before attempting removal. An
indexing arrow is located on the top of
the module for this purpose.
b. Position Special Tool 9340 into the
notches on the outside edge of the lock
ring (Figure 10).
c. Install a 1/2 inch drive breaker bar to
Special Tool 9340.
d. Rotate the breaker bar counter-clockwise to loosen the lock ring.
e. Remove the lock ring.
NOTE: The module will spring up slightly when the lock ring is removed.
f. Lift the fuel pump module from the fuel tank.
CAUTION: Be careful not to bend the float arm while removing the fuel
pump module.
12. Discard the old tank using an environmentally safe method.
13. Remove the new fuel tank from its packaging.
14. Install a new seal into the fuel pump module opening.
15. Position the fuel pump module into the opening in the fuel tank.
16. Position the lock ring over the top of the fuel pump module.
17. Rotate the module until the embossed alignment arrow points to the center
alignment mark.
NOTE: The pump module must be indexed to prevent the fuel gauge float
from contacting the side of the fuel tank. Also be sure the fuel fitting on the
top of the pump module is pointing towards the driver’s side of the vehicle.
18. Using Special Tool 9340 and a 1/2 inch breaker bar, tighten the lock ring
(clockwise) until all seven notches have engaged.
Service Procedure (Continued)
Figure 10 – Fuel Pump Module
Safety Recall H45 – Fuel Tank Inlet Check Valve Page 12
19. Transfer the NVLD pump, canister and canister vent line located on the front of the
old fuel tank to the new fuel tank.
20. Transfer the heat shields from the old tank to the new tank.
21. Place the fuel tank assembly onto the hydraulic jack.
22. Carefully raise the tank until positioned near the body.
23. Connect the EVAP, ORVR and NVLD hoses and electrical connector located at
the front of the tank.
24. Connect the fuel pump module electrical connector located at the top of the tank.
25. Connect the fuel line quick-connect fitting to the pump module.
26. Connect the fuel fill tube while raising the fuel tank into position. Continue
raising the fuel tank until it is positioned snug against the floor pan.
27. Install and position both fuel tank support straps.
28. Install the fuel tank strap retaining bolts and tighten bolts to 30 ft. lbs. (41 N·m).
29. Position and tighten the fuel filler tube hose clamps (Figure 8).
30. Connect the fuel tank vent hose located next to the fuel fill tube (Figure 8).
31. If equipped, install the fuel tank skid plate. Tighten the bolts to 30 ft. lbs. (41 N·m).
32. Lower the vehicle and refill the fuel tank with the fuel that was removed.
33. Start the engine and check for leaks at the fuel tank and pump module area.
34. Connect the StarSCAN diagnostic tool and check all modules for Diagnostic
Trouble Codes (DTC’s).
NOTE: When the fuel pump relay was removed to release the fuel system
pressure, a Diagnostic Trouble Code (DTC) may have been set. Some DTC’s
may cause the Malfunction Indicator Lamp to illuminate. Check all modules
using “System View” from the ”Home” screen, record the DTC’s, and erase
these DTC’s prior to returning the vehicle to the customer. Erase any DTC’s
in the Powertrain Control Module only after all other modules have had their
DTC’s erased.
Service Procedure (Continued)
Safety Recall H45 – Fuel Tank Inlet Check Valve Page 13
Claims for vehicles that have been serviced must be submitted on the
DealerCONNECT Claim Entry Screen located on the Service tab. Claims
submitted will be used by Chrysler to record recall service completions and
provide dealer payments.
Use one of the following labor operation numbers and time allowances:
Labor Operation Time
Number Allowance
Test Fuel tank Inlet Check
Valve Operation
Test Fuel tank Inlet Check
Valve Operation and Replace
Fuel Tank (without skid plate)
Test Fuel tank Inlet Check
Valve Operation and Replace
Fuel Tank (with skid plate)
Add the cost of the recall parts package plus applicable dealer allowance to your claim.
NOTE: See the Warranty Administration Manual, Recall Claim Processing
Section, for complete recall claim processing instructions.
To view this notification on DealerCONNECT, select “Global Recall System” on
the Service tab, then click on the description of this notification.
Completion Reporting and Reimbursement
Dealer Notification
Safety Recall H45 – Fuel Tank Inlet Check Valve Page 14
All involved vehicle owners known to Chrysler are being notified of the service
requirement by first class mail. They are requested to schedule appointments for this
service with their dealers. A generic copy of the owner letter is attached.
Enclosed with each owner letter is an Owner Notification postcard to allow owners
to update our records if applicable.
All involved vehicles have been entered into the DealerCONNECT Global Recall
System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed.
GRS provides involved dealers with an updated VIN list of their incomplete
vehicles. The owner’s name, address and phone number are listed if known.
Completed vehicles are removed from GRS within several days of repair claim
submission.
To use this system, click on the “Service” tab and then click on “Global Recall
System.” Your dealer’s VIN list for each recall displayed can be sorted by: those
vehicles that were unsold at recall launch, those with a phone number, city, zip
code, or VIN sequence.
Dealers must perform this repair on all unsold vehicles before retail delivery.
Dealers should also use the VIN list to follow up with all owners to schedule
appointments for this repair.
Recall VIN lists may contain confidential, restricted owner name and address information that
was obtained from the Department of Motor Vehicles of various states. Use of this information
is permitted for this recall only and is strictly prohibited from all other use.
If you have any questions or need assistance in completing this action, please
contact your Service and Parts District Manager.
Customer Services Field Operations
Chrysler
Owner Notification and Service Scheduling
Vehicle Lists, Global Recall System, VIP and Dealer Follow Up
Additional Information
SAFETY RECALL H45 – FUEL TANK INLET CHECK VALVE
Dear: (Name)
This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle
Safety Act.
Chrysler has decided that a defect, which relates to motor vehicle safety, exists in some 2005 model year
Dodge Durango vehicles.
The problem is... The fuel tank inlet check valve on your vehicle (VIN: xxxxxxxxxxxxxxxxx) may
stick in the open position. This can cause fuel to spill out of the filler tube when the
vehicle is being refueled. Fuel in the presence of an ignition source can result in a
fire.
What your dealer
will do...
Chrysler will repair your vehicle free of charge (parts and labor). To do this, your
dealer will test your vehicle’s inlet check valve and replace the fuel tank if necessary.
The test will take about an hour to complete and fuel tank replacement, if required, will
take another hour. However, additional time may be necessary depending on service
schedules.
What you must
do to ensure your
safety...
Simply contact your dealer right away to schedule a service appointment. Ask the
dealer to hold the part for your vehicle or to order it before your appointment.
Remember to bring this letter with you to your dealer.
If you need help... If you have questions or concerns which your dealer is unable to resolve, please contact
Chrysler at 1-800-853-1403.
Please help us update our records by filling out the attached prepaid postcard, if any of the conditions listed
on the card apply to you or your vehicle. You may also update this information on the web at
CCCCCCCCCCCCCCCCCCCCCCCCCC
If you have already experienced this condition and have paid to have it repaired, you may send your original
receipts and/or other adequate proof of payment to the following address for reimbursement: Chrysler Recall
Customer Assistance, P.O. Box 21-8007, Auburn Hills, MI 48321-8007, Attention: Reimbursement.
If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may
submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 1200 New
Jersey Ave., S.E., Washington, DC 20590, or call the toll-free Vehicle Safety Hotline at 1-888-327-4236
(TTY 1-800-424-9153), or go to http://www.safercar.gov.
We're sorry for any inconvenience, but we are sincerely concerned about your safety. Thank you for your
attention to this important matter.
Customer Services Field Operations
Chrysler
Notification Code H45
Note to lessors receiving this recall: Federal regulation requires that you forward this recall notice to the lessee within 10 days.

 

Had no overflow problems since about April. Today was just about freezing when filling up and it burped gas the worst yet. All down the side of the truck. What a freakin' mess.

 

Just got the truck back from the dealer. They are ordering a new tank and filler neck and should be replaced Wednesday.

I have a 3rd party warranty through CNA and they are covering it less $100 deductible.

No resistance or complaints from the dealer. I'm sure if I didn't have a 3rd party they would have.

I'll take $100 for my family safety.

I have notified SRS of my situation. Definitely need to keep up the fight for others not under warranty.

This is a safety issue.

 

I have a Durango 2007 and my fuel tank has been spilling out when I put fuel in and the nozzle shuts off. I has an appointment with the Dodge dealer this afternoon to look into the problem. Is there a safety notice on this from any Gov't Agency?
Thanks,
Gary Lee

 

NO.

No offense, but you really should take the time to read through the entire thread to educate yourself. Lots has been written here.

 

Got my Durango back yesterday. $100 deductible through my 3rd party warranty.

They said the rollover values were defective. Duh go figure and yet he didn't seem to think it should be recalled.

My bill would have been $960 without the warranty

 

I had this same issue with my 2006 Durango. Luckily my 3rd party warranty covered the fix. It took two trips into service to get it fixed, but it seems to be fine now.

I took it in originally after reading about the issues others were having. The dealership confirmed the problem and ended up replacing the entire fuel tank. I picked the vehicle up, drove it for a week and filled it up. No problem, the pump shut off and no gas spillage. I was happy. Then, about a week later, I filled up again. This time I couldn't even put gas in it. The pump constantly shut off. It took me almost 15 minutes to put 10 gallons of gas in it! I immediately took it back into service. After a couple of days, they told me it was all fixed up (again). I went in to pick it up and was told that a hose was pinched. That was a couple of months ago. I've filled up several times since and haven't had a single issue. My bill would have been close to $1,000 as well.