Ha, another problem with the van. For the last year the fuel tank always overflows at the gas station as I'm filling it up. This happens at the end of a complete fill and I've got the handle held wide-open (In Ontario self-serve stations are not permitted to have locking handles so we have to hold them...). The end result is a good ejection of fuel when I hit full which is rather hazardous so I don't let my wife stay in the van when filling. Is there anything in the filler neck that can fail? I tried shining a light around the fuel filler lines on the inside of the fender and I couldn't see any light inside the fuel filler to indicate a broken line.
Thanks, Steve

 

I've occasionally had the opposite, where I'd have difficulty filling rather than what you are dealing with Steve. Admittedly don't know much (if anything) on this subject but some of the searches I've pulled up concerning your overflow issue (Dodge, but not our B vans) suggest it's likely the check valve in the tank which is not repairable so replacing the tank solves the issue... maybe not the case for you idk?

I'm sure you already know but just be safe and keep of track of mpg's so you can fill close but not to the spill point until you can find an answer

 

Does this happen at any gas station or the same one all the time?

 

It happens everywhere with many styles of pumps. We were down to Tennessee recently so I got to try lots of pumps.

 

Then it's most likely the tank vent tube is clogged. It runs parallel to the filler neck to allow air to escape as fuel is being put in. Here is an example of the filler tube with the vent tube alongside it.

 

Finally got back to this. I removed the fill pipe but found it wasn't blocked at all. The hoses were not either. What did surprise me was that the pipe that "connects" to the tank is just stuffed in through a foam gasket! I decided to paint the pipe as its somewhat expensive. I did add an extra gear clamp on the foam as it was just a slide fit and was kind of weird to me. When I went to fill up the tank I didn't get any overflow but the gas station I went to was very slow at pumping. I filled the van with premium for the winter so I won't know if this worked out until next summer.

 

What is the make, model and year? My 2005 Durango 5.7 did that and it turned out there was a recall on the entire fuel tank that fixed the issue.

 

I am not aware of any recalls or TSBs, it is a 1991 Dodge B250. I am starting to think this began happening around the same time I replaced the front suspension so perhaps it is related to the stance of the vehicle. The tank has never read more than about 7/8's of a tank in the past 20 years either.

 

the purpose of the that tube is refueling vapour recovery...it prevents fumes from escaping to atmosphere when refueling. the tank should vent air thru a evap cannister when refueling not the atmosphere.
pressure build up in the tank is what shuts the pump off.

 

I did some investigating today and there are three lines that route from the tank up to the front of the van. There is the fuel supply, fuel return, and also the vapour recovery. The vapour recovery line appears to be something like 1/8" ID so I do not feel that it can be the issue.

The next step is probably to bring some boards to the gas station and park on them to raise the left rear wheel when fuelling.