My 04 Rango started having a fuel system issue. It will not fill completely, stops at 3/4 to 7/8 of a tank, and has started to use lots of fuel, to the point where I fill up, and use 1/4 tank to drive 20 miles. Exhaust pipe is solid black inside, dealer said that the "fuel level sending unit" and tank had to be replaced, but nothing was found on the fuel usage. No lights have come on, and according to the code computer, there is nothing wrong. Was told in excess of $1200 for tank system. Not so much worried about the tank as I am the fuel usage, sucks watching the gauge move when I start it. Any advice would be helpful...
Thanks

 

You seem to be having TWO issues and not just one. Issue 1 is not getting the tank to fill to the top and Issue 2 is burning off the fuel fast after you do get it into the tank.

Before I would spend $1200 for a tank that NO ONE has ever heard of failing, usually high fuel usage can be traced. Check one of the following:

Issue 1

- Gas pumps have a fail-safe to sense pressure from the vapor to shut off the pump before overflow/overfill. If your check-valve isn't letting some vapor escape into the canister, then that is the issue on the fill up. To much pressure and vapor is built up tripping the pump sensor. Also if there is a loose/broken/clogged/missing hose from the setup to the canister that can be causing it too. Investigate all the hose connections to and from the fuel canister next to the tank.

- You could be simply loosing the fuel.
NHTSA Campaign ID Number: 05V034000
Recall Date: 02/01/05
Component: Fuel System, Gasoline:Storage:Tank Assembly:Filler Pipe and Cap
Potential Number Of Units Affected: 26000
Summary: On certain sport utility vehicles, the fuel tank filler tube inlet check valve may not fully close at the end of refueling. This could allow some fuel to escape from the vehicle filler neck.
Consequence: Fuel leakage in the presence of an ignition source can result in a fire.
Remedy: Dealers will inspect the inlet check valves and replace the fuel tank assembly free of charge. The recall began on April 4, 2005. Owners may contact DaimlerChrysler at 1-800-853-1403.
Notes: DaimlerChrysler recall # E01.

- I recall reading in a forum a few years back about a Gen2 problem filling up fuel to the top. It isn't common but it has happened. Search is your friend.

Issue 2

- The exhaust pipe being soild black points to burned fuel and not lost fuel. It also says O2 sensor failure. You may have 2 to 4 of them. When an O2 sensor fails, it usually sends back a code. However, if it doesn't know it has failed, then that could be sending back signals interpreted as a need for more fuel. Replace 02s.

- TB sensors telling the PCM to add fuel for a cold running/warm up situation. This is akin to the old "choke" on a carb but since we are all electronically controlled, the sensors do it all. Replace MAP & IAT sensor


$20 says you spending $1200 on a tank setup isn't going to do anything. BTW, a new tank and neck on the recall above is rated out at $400, not $1200. Where are they getting $1200 from? Crooks. Go somewhere else and never go back to that place again.

IndyDurango USA MOS 72E, 1985-1987

 

Sorry for just NOW responding to this post. SO many things have happened since I posted this issue.

First, thank you for the response.

Second, as I lived in California, I took my Rango and had a smog test performed to see what kind of results that gave me. Everything went great, and it passed with flying colors. So I knew the O2 sensors were fine.

Third: I took the Durango to CarMax where I purchased it (big mistake). They are the ones that told me to "live with it" or pay "$1200 to repair it". This entailed dropping the tank, replacing the fuel level sending unit which is also part of the fuel pump, and "advised" replaing the tank. Then, they told me that it was all one piece and that they could ONLY replace the whole thing (tank and pump/sending unit).

Since then I have been filling it to the max myself. I am still not getting the reading from the computer that I used to. Prior to the issue, when it was full, I would get 408 miles to a tank. Now I am lucky if it reads 360. I was able to find the part (fuel pump/sending unit) online for around $400, but finding a shop that wont bend me over to do the work is another question since they have to drop the tank.

As for the recall, I have looked and even signed up for automatic notifications of recalls. I contacted one dealer when I was in Cal, and they told me that it was not listed under any recalls, and that my VIN was not triggering any notifications.

So I am currently driving it as-is until I can afford to actually get the sending unit fixed...

 

Nice to hear back from you. No problem on the timeline. In fact, since you have been gone, many others have reported the same fuel problem with their Gen2 Ds. The NTSB has started tracking for a recall AND some folks have been successful in getting Chrysler to replace everything for a small nominal fee ($200 IIRC.) SOME have even been sent refunds for work past preformed.

A couple of things, review the forum for more posts from others with similar issues. Also, go to a good dealer and see if they are aware of the situation. If so, start there in getting yours corrected. If you don't get any help there, try another dealer AND start contacting Chrysler's customer care center for more help.

Good luck and check back in again soon!

Happy to help.

IndyDurango

 

Wow!!! Thanks for the help. I well start researching it today and with any luck get it fixed soon!

 

I posted previously, "Need Help Bad", about my 04 having a issue with what I thought was fuel mileage. Turns out it is the fuel level sending that has been causing it all along. The fuel tank will not fill completely, causing me to "top off".
I was informed that the NTHSB is aware and that some Gen 2 owners have had success getting the issue resolved. If you have had this , abs got it resolved, post what you did. I will be contacting dealers today to hopefully get this fixed.

 

Merged the threads. If its still dealing with the same issue, please post in your existing thread, and do not create another.

 

There are two threads about the fuel purging after fill up, if that is your problem.
FF

 

Its not purging, just won't fill completely. Stops at 3/4-7/8, I end up having to "top off".

 

Just trying to get an idea of how many people had the same issue but were able to get it resolved... Sorry.