Here is a TSB, Remember your body style is a HB not a LX. There is also a recall H45 that i will post later. This is for the filling problem not, the using a 1/4 after 20 miles.


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

 

Here is the recall notice. You need to check with your local dealer to see if it applys.

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
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.

 

Awesome!!!! I'm going to call first thing tomorrow and ask about it. With any luck I will get this thing fixed sooner rather than later!!! Props to you Master Tech!

 

My Durango was manufactured 02/2004... Fingers crossed one of the dealers around here step up and take care of the issue...

 

Well, called two dealers today. Both shot me down on the recall and TSA you told me . One told me that from what I says, it sounds like it could be the filler neck, evap tube, and fuel level sending unit. He recommended replacing all if it, tank included at a cost of more than $2000. If I do the filler neck, evap tube and sending unit, i'm looking at almost $1000. The tank alone is over $1700 for parts and labor. Looks like I drive it broke for a while. Been doing it for over two years already... Another couple won't hurt.

 

Armyvet:

Do not give up just yet. Although your Durango is an 04, many, many folks have been getting most if not all of this cost waived by contacting Chrysler Customer Assistance and politely but firmly making their case.

Usually, they end up paying $500 or less and some have ended up paying $0.
Take a good look at and digest this thread from this forum.

https://dodgeforum.com/forum/2nd-gen...6-durango.html

In the end, if you cannot get Chrysler to help you, there are alternatives posted in this thread.
One of them being a factory replacement tank for $88 + shipping that will do just fine with a little work.

Don

 

Looks like a lot of Durangos have the same issue. Sad that mine might be the fuel level sending unit and not the filler neck or tank.

 

I have a 2005 Durango Hemi -- Limited. In the winter of 2011 we found that it would spray fuel all over before engaging the automatic pump shut off. Nobody wanted to fill the tank. Not me. Not my wife. Not my daughter. I took it to my mechanic (not Dodge) who confirmed the problem and told me about the tank recall. I went to Dodge, who told me that my car was not built within the dates covered by the recall. However the dealer determined that the fuel tank and filler neck needed to be be replaced. BUT HE COULD NOT LOCATE A REPLACEMENT and so the car sat in the dealer three weeks waiting for the part. I called Dodge customer assistance and got nowhere about locating a part. I started searching the Internet and found a tank with the right part number -- only it was at an out of state dealer. I went back to my dealer and told them they needed to call the dealer I'd listed. They did and the tank came in a few days. After paying $500 for parts & installation, I picked up the car and immediately went to fill the tank. I found that the tank would now fill only at an incredible slow rate, or the pump would shut off. I went right back to the dealer, who told me that we must have gotten a bad tank (DUH), which they could do nothing about because Chrysler parts were hard to get supposedly due to the bankruptcy. At this point I asked for the service manager, head of sales and/or the dealer owner. I indicated that my car had been there for a month. I was polite, but I did threaten them and Dodge with a lawsuit. I needed a car NOW. I'd been patient to a fault. As it was Saturday afternoon, I told them I knew that they could not get parts until Monday. I said I wanted a phone call by noon Monday with news of how they were going to replace the tank. They noted the presence of another 05 used Durango on the lot, but it was not a Hemi. I suggested that we trade that one for mine until my parts came in, or we simply take the tank from that car for mine. One way or the other I needed a car. I don't know what the dealer did between Saturday afternoon and Monday, but I got a call from the manager at noon, who told me that my car would be be ready for pickup by Wednesday afternoon. I filled it immediately, and it has filled up fine ever since.