My 06 did this since I purchased it in 2007 still under warranty. I complained, but of course Dodge never "documented" my complaint. This past March, 6 weeks out of the 5 year rust through warranty, bubbles started showing up on the fender under the fuel filler door. In April they started oozing rust. I called Dodge and kept complaining my 06 came off the assembly line 11/05 and I'm pretty sure I got an 05 gas tank which was under the recall. They kept telling me no, until finally, they said have the local dealer look at it. I had to take the service manage with me to fill up to show him how it spews! This did the trick, Dodge agreed to replace the tank and fix the rust, I talked them down to a $200 deductible. Well after they replaced the tank (turns out it wasn't even a tank spec'd for a Durango) the rust was through both sides of the rear quarter panel and the body shop wouldn't just fix the cosmetic fix that Dodge wanted them to do. They ended up okaying and replaced the entire rear quarter panel.

Keep complaining!!!!!! I kept saying to Dodge customer service about personal safety and environmental hazards and no other vehicle I have owned ever did this.

 

Mine started to bubble in the same area a few weeks ago. I noticed it while I was filling it up,
FF

 

I bought mine used 3 days ago and filled it up today. Yep, covered my foot in gas.

I am not going to mess with it until I come home from deployment in October.

 

When I first bought mine in May it did the overflow thing. After about a month it "cured" itself and was a normal gas tank for about four months. Now it is doing the overflow dance again. Frustrating.

 

Hi. New to the forum. Trying to read up on this problem. Just bought a used 06 Durango. First three fill ups were overfills. Tried "burping" on the fourth fill. I put in about 15 gallons, removed the nozle for about 10 seconds then put another 5 gallons after that with no trouble. Seems like a good solution for the time being. Wondering if something is really wrong in there and I should fight the fight to get the tank replaced. Will keep reading these pages (only read about 5 of the 20 so far on this issue). Keep the info coming! Thanks.

 

JM, that may work in your state, but in New Jersey, where it is a law that you cannot pump your own gas, it means one deals with not filling up their tank all of the way or getting gas all over the place.

I have called Chrysler 3 times now and have been told that they won't help. I was told that it is my fault I bought a used vehicle without a bumper to bumper warranty. I am brand loyal, but this is really pissing me off. I know all cars have issues, but when it comes to SAFETY and factory defects, there shouldn't be any questions about who should fix it. If the transmission fell out, I would not complain; it is a wear item. A gas tank is not a wear item.

I told the one guy on the phone that I was brand loyal and his response was, "Our system only shows that you purchased one Dodge, ever". I responded, "I have owned a 1998 Dakota, a 2003 Ram, a 2005 Ram, a 2009 Ram, a 2004 SRT-4 Neon, a 2006 Chrysler Pacifica, and still have a 1971 Dodge Dart in my garage at home". Chrysler guy replies, "Well, my system only shows one so I can't agree you are brand loyal". Nice.

 

Complaint filed with NHTSA. It takes 2 minutes. I suggest everyone with this problem does it as well.

 

New Member Here...

I have a 06 Durango SLT with about 73k miles

Just searching the web and came across this thread.. Same thing started happening to me around 2 or 3 months ago...It seems like 4 out of every 5 fill ups it will overfill.

Also around the same time i started getting code P0456 check engine light. Emissions leak or something along those lines. I tried looking for the evaperator canister but read conflicting reports over at dodg3talk on where to find it. I replaced the gas cap also as i heard that usually was the cause of that code.

Today i saw GASCAP show up were the odometer usually reads....

No way I am going to dump $1000 into this thing though for a gas tank, or anything else for that matter. I will just trade it in if that all needs to get done..and by the sounds of it none of that is even fixing the problem.

**EDIT**

Also just to mention..Whenever i reset the the PCM it will clear the code and will stay off up until the tank gets around 1/4 of a tank every time.

 

Today I filled it when the gas light came on. I know it will take 22 gallons once the light is on. I slow down the pump (as long as I am not in Jersey where you cannot pump your own gas...) and listen for it coming up the tube and stop it. I like to check my gas mileage, so this method is not going to be the most accurate, but better than nothing.

 

Even though mine was covered under a 3rd party warranty and has since been fixed, I still filed the claim in hope it might help others.