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moderate 537 complaints filed with NHTSA · avg repair $1,200 · see fuel system across all vehicles →
Of the 537 fuel system complaints filed for the 2005 Dodge Durango, here's the actual mileage breakdown — failures cluster heaviest at 75,000-100,000 mi.
Each bar shows the share of total complaints filed at that mileage range. Peak failure window highlighted. Some owners report problems earlier; some make it well past 150,000 miles symptom-free. Maintenance habits and driving conditions shift the curve as much as mileage alone.
Cumulative share of the 10 mileage-bearing fuel system complaints filed against the 2005 Dodge Durango by each odometer reading. Median failure: 85,000 mi.
Curve based on owner-reported odometer mileage at the time of complaint. Reflects when owners filed, not when symptoms first appeared. Maintenance habits and driving conditions shift the curve.
Of the 8 model years of Dodge Durango we track for fuel system problems, this one carries the most owner complaints on file — 537.
Fuel system accounts for 34% of every owner complaint on file for this vehicle — the dominant problem area across 12 categories tracked.
Fuel leakage in the presence of an ignition source can result in a fire.
Fuel leakage in the presence of an ignition source can result in a fire.
The manufacturer has issued service bulletins covering fuel system on this vehicle — documented repair instructions, service campaigns, or warranty extensions sent to dealers. A TSB isn't a recall (it's not a free safety remedy), but it's the manufacturer acknowledging the issue and how to fix it.
SUMMARY TO BE PROVIDED ON A FUTURE DATE.
full bulletin at NHTSA ↗Fuel Spit Back During Refueling Due To Inlet Check Valve (X48 Lifetime Warranty Extension) This bulletin involves replacing the fuel filler tube if the condition occurs.When removing the existing fuel filler tube note how it comes out to aid in installation of the new part. Some customers may experience a fuel spit back condition during a refueling event.
full bulletin at NHTSA ↗Fuel Spit Back During Refueling Due To Inlet Check Valve (X48 Lifetime Warranty Extension) This bulletin involves replacing the fuel filler tube if the condition occurs.When removing the existing fuel filler tube note how it comes out to aid in installation of the new part. Some customers may experience a fuel spit back condition during a refueling event.
full bulletin at NHTSA ↗Fuel Spit Back During Refueling Due To Inlet Check Valve (X48 Lifetime Warranty Extension) This bulletin involves replacing the fuel filler tube if the condition occurs.When removing the existing fuel filler tube note how it comes out to aid in installation of the new part. Some customers may experience a fuel spit back condition during a refueling event.
full bulletin at NHTSA ↗JEEP: SEE DOCUMENT SEARCH BUTTON FOR OWNER LETTER. DUE TO INLET CHECK VALVE, WHEN REFUELING VEHICLE, THE FUEL WOULD SPIT BACK AND THE FUEL FILLER TUBE NEEDS TO BE REPLACED. MODEL 2005-2006 DURANGO.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The 2005 Durango has two major fuel-system failure patterns. The first and most prevalent: the fuel tank filler tube inlet check valve fails to close properly, allowing fuel to spray, gush, or pour out the filler neck at the end of every refuel—sometimes a half-gallon at a time, often with force. Owners report getting drenched in gasoline, even hit in the face or eyes, and fuel pooling around the pump and vehicle. This happens regardless of fuel station, pump type, or fuel level. Chrysler recalled vehicles built March 2004 through October 12, 2004, then expanded the recall in 2009 to October 13–November 30, 2004. But owners of 2005 model-year vehicles built after November 2004 experience identical failure and are denied recall coverage. Repair requires fuel tank replacement, quoted at $650–$1,200.
The second pattern: fuel tank overfill blockage prevents proper filling, with the pump shutting off early or fuel backing up in the filler tube, making it impossible to know if the tank is truly full.
A third complaint thread involves engine stalling without warning during low-speed turns or backing, with power steering loss and no warning light. Owners report 10+ instances. One mechanic's EGR valve replacement temporarily helped, but the problem recurred.
Check engine lights accompanied by O2 sensor codes and exhaust pinhole leaks also recur despite repair attempts—light reappears within days or weeks.
Same Dodge Durango fuel system reports on nearby years: 2006 · 2007 · 2008
The fuel tank filler tube inlet check valve fails to fully close at the end of refueling, allowing fuel to escape from the filler neck. Owners report fuel gushing, spraying, or pouring out with force—sometimes several ounces to a half-gallon per event—drenching people, vehicles, and ground every time they fill up. Several owners were hit in the face or eyes. The failure occurs at any fuel pump type (automatic shut-off or manual), at any fuel level (some report it starting when tank is half-full), and with no warning signs.
When: Failures reported starting anywhere from purchase to 40,000 miles; occurs repeatedly at every refueling
Symptoms owners cite: Fuel sprays or gushes out of filler neck when pump nozzle stops; Fuel spills down vehicle exterior and onto ground; High-pressure spray or fountain of fuel; Fuel makes contact with skin, clothing, face, or eyes; Occurs at every fuel stop, regardless of fuel station or pump type; Sometimes accompanied by loud venting sound from tank; No warning lights or malfunction indicators
Repairs/costs cited: Dealers diagnosed as faulty inlet check valve; remedy is fuel tank replacement. Quoted repair costs range $650–$1,200 for tank and labor. Some owners report tank replacement alone cost ~$800–$900. A few owners had tank replaced under recall or goodwill, yet problem recurred, suggesting either same defective part was reinstalled or filler tube/assembly also requires replacement. One owner reported dealer quoted $264 for filler tube parts after tank was already replaced under recall.
Recalls/TSBs owners mention: Chrysler issued two separate recalls: 05V-034 (March 2005) for vehicles built 3/1/04–10/12/04, and 09V-003 (January 2009, expanded to 10/13/04–11/30/04). Chrysler claimed process modifications on 11/24/04 resolved the issue, but many vehicles built after 11/30/04 and even into 2005 exhibit the identical problem and are not covered by either recall. Vehicles with VINs outside recall ranges were repeatedly denied coverage despite identical symptoms and same 2005 model year. Chrysler offered partial reimbursement ($140–$350) to some owners but refused full repair coverage. One owner received goodwill repair only after threatening small claims court. Dealer TSB #14-001-09 exists but only covers certain VIN ranges. One service manager reportedly told an owner to have fuel lines rigged with piping to block airflow (described as dangerous workaround).
Tank backs up during refueling, preventing the pump from recognizing when tank is truly full. Owners report the pump shuts off prematurely or fuel backs up in the filler stem, making it impossible to know whether the tank is genuinely full or just blocked. In some cases, filling to even three-quarters capacity triggers the spitback issue.
When: Present from time of purchase or early ownership; some failures noted after 40,000 miles
Symptoms owners cite: Pump shuts off before tank is full; Fuel backs up in filler stem/tube; Difficult to distinguish true full level from backup blockage; Must pump and let go multiple times (every dollar or few seconds) to add fuel slowly; Even partial fills (less than three-quarters tank) can trigger spitback; Vent vent system appears to prevent proper tank filling
Repairs/costs cited: One owner had tank replaced under recall at a dealer, problem persisted. Another had an EVAP leak diagnosed and sealed, then a second fuel tank replacement; problems continued. Multiple owners report managing the problem by filling only to three-quarters capacity to avoid spitback, despite safety concerns about running low on fuel for long-distance driving.
Recalls/TSBs owners mention: No specific TSB or warranty coverage mentioned for overfill symptom in these narratives. Dealers suggested new fuel tank, but replacement has not consistently resolved issue.
Engine stalls without warning during slow-speed turning, backing up, or low-speed maneuvering. Steering becomes impossible while stalled. Owners report 10+ instances over months of ownership. No check engine light or malfunction warning prior to event. Problem occurs on curvy roads, in driveways, at intersections, and on inclines. In one case, owner nearly lost control on a mountain road.
When: Multiple instances reported from purchase through years of ownership; one owner noted problem was worse in later complaint submissions
Symptoms owners cite: Sudden engine shut-off during low-speed turning or backing; No steering assist when stalled (power steering loss); No warning lights or check engine indication before stall; Vehicle must be restarted with ignition key; Occurs at intersections, driveways, mountain curves, and slow climbs
Repairs/costs cited: One owner reported a mechanic replaced the EGR valve and problem was temporarily fixed, but later recurred. No permanent repair identified in narratives.
Recalls/TSBs owners mention: No manufacturer response documented. One NHTSA investigation was opened and closed (RQ08005, but records indicate stalling complaints continued post-closure). Owners note there are multiple open and closed NHTSA investigations on this issue, yet no recall issued.
Check engine light comes on repeatedly, often with diagnostic codes pointing to O2 sensor problems. Service records indicate exhaust system pinhole leaks; dealer repairs are temporary. After repair or sensor replacement, light reappears within days or weeks. In one case, a service manager suggested an unsafe modification (rigging fuel lines with internal piping to block airflow) and threatened to deny knowledge if reported.
When: Multiple occurrences within days to weeks of repair attempts; occurred after Dodge performed initial alterations to vehicle
Symptoms owners cite: Check engine light illuminates; Diagnostic code points to O2 sensor malfunction; Engine stalls during operation; Light reappears 200 miles or days after repair; Loud venting sound from tank area (in one case)
Codes mentioned: O2 sensor malfunction codes (not specified in detail)
Repairs/costs cited: Dealer replaced O2 sensor. Then Dodge contacted DaimlerChrysler, which ordered exhaust leak inspection. Pinhole leaks found and sealed. Problem recurred. Second exhaust inspection found another pinhole leak; entire exhaust was sealed. Problem still recurred. Service manager suggested internal fuel line modification as unsafe workaround and denied knowledge if reported. No further successful repair documented.
Recalls/TSBs owners mention: DaimlerChrysler authorized multiple exhaust leak inspections and temporary sealing repairs. When leaks recurred, suggested internal fuel line rigging (dangerous workaround). Declined further rental car coverage and pressured owner to take unsafe vehicle.
Synthesized from 537 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
My 2005 Dodge durango limited (hemi) spews about 1 quart of gas out of the filler tube every time I fill up with gas. Dealer says my VIN # ( mfg. Date 3/05) is not covered by their 1st or 2nd recall. I called Chrysler's customer care @ 1-800-853-1403 and was told although I appear to have the problem associated with the recall, they will not do anything because my vehicle now has 150,000 miles…
Each time we fill the fuel tank of our 2005 Dodge durango the tank over flows and fuel comes pouring out around the refueling nozzle and spills out onto the car and all over the ground. This is a potentially hazardous situation in that at least half a gallon of fuel that spiills out that could ignite and spread to the fuel tank and cause an explosion. Fortuneately it is winter now, but in the…
Tl*the contact owns 2005 Dodge durango. The contact stated that when fuel was added to the vehicle the fuel tank would not shut off when the vehicle was full. The failure caused gasoline to spill out of the fuel tank. The vehicle was not repaired. The manufacturer was contacted and stated that they are aware of the failure and that there was a recall for the failure but his vehicle was not…
Every time I fill up with gas, fuel comes gushing out of my fuel tank. At first, I thought it was the gas station nozzle, but realized that after using several different stations, this was not the case. After completing some research online, I saw there was a safety recall issued for this same complaint. I then contacted Chrysler and was informed that the VIN on my vehicle was not covered…
Anytime I fuel, my j2005 durango spits a lot gasoline out of the filler neck. It does not matter how fast I fuel or whether or not I top off the tank. I called Dodge and was told that Chrysler/Dodge will not include my 2005 durango vehicle in the fuel tank recall as noted in your campaign number 09v003000 or 05v3400, even though I had the same issue the recalls were to fix. I was told my…
Tl*the contact owns a 2005 Dodge durango. Whenever the contact fills the fuel tank, gasoline sprays out of the tank. The fuel nozzle stops when the tank is full, but gasoline continues to spray out of the tank. Through research, the contact discovered NHTSA campaign id number 05v034000 (fuel system, gasoline;storage;tank assembly;filler pipe and cap). The VIN was not included in the recall,…
Every time I went to fill the gas tank it had a delay overflow . Started out with about a cup of gasoline and then increased to about 3/4 of a pint and this is even when filling very slowly. I checked online and found that there had been a recall on durango's in 2005 for gas tanks overflowing because of a defective check valve. When I contacted the dealer he said that recall did not apply to…
Tl* the contact owns a 2005 Dodge durango. The contact stated that while refueling the vehicle, fuel was spewed from the fuel tank abnormally. The vehicle was not taken to the dealer. The manufacturer was contacted and confirmed to the contact that the VIN did not qualify for repairs under NHTSA campaign id number: 09v003000 (fuel system, gasoline:storage:tank assembly). The vehicle was not…
Tl*the contact owns a 2005 Dodge durango. The contact stated whenever dispensing fuel into the fuel tank to the full capacity, the fuel would abruptly spill out of the filler neck. The vehicle was not diagnosed or repaired. The failure mileage was approximately 85,000.
Fuel splashes up the filler when refueling - started in november 2010 and has occurred on last 4 fill-ups. *tr
It's a documented issue but not catastrophic. 537 complaints have been filed. Repairs average $1,200 and most owners catch it before it causes a breakdown.
Across the 467 complaints that reported odometer mileage, most fuel system failures cluster between 50,000 and 89,000 miles, with the median around 68,000. A quarter of owners report trouble before 50,000; a quarter make it past 89,000. Maintenance history matters more than the odometer alone — this is the reported failure window, not a guarantee.
Independent shops typically charge around $1,200 for fuel system repairs on this vehicle. Dealer pricing tends to run 20-40% higher. The exact figure depends on the specific failure mode, parts availability, and your local labor rates. If you're outside factory warranty, an extended service contract often covers this category.
Yes — 2 active recall(s) cover fuel system issues on this vehicle. Recall fixes are always free regardless of mileage or warranty status. Use the VIN decoder at the top of the page to check if your specific vehicle is affected.