CHRYSLER/DODGE: FUEL TANK INLET CHECK VALVE (FUEL FILLER TUBE). UPDATED 8/17/12.
full bulletin at NHTSA ↗2007 Chrysler Aspen fuel system problems
moderate 64 complaints filed with NHTSA · avg repair $1,200 · see fuel system across all vehicles →
Failure mileage
Complaints
64
Recalls
0
Avg fix
$1,200
When does it fail?
Of the 64 fuel system complaints filed for the 2007 Chrysler Aspen, here's the actual mileage breakdown — failures cluster heaviest at 25,000-50,000 mi.
0-25k
25-50k
50-75k
75-100k
100-125k
125-150k
150k+
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.
How fast does it fail?
Cumulative share of the 11 mileage-bearing fuel system complaints filed against the 2007 Chrysler Aspen by each odometer reading. Median failure: 41,000 mi.
10% have failed by30,000 mi
Half the fleet by41,000 mi
90% have failed by54,891 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.
What stands out
Owners have filed 64 fuel system complaints with NHTSA against this vehicle, but no formal recall covers the issue — the federal record reflects what manufacturers have admitted, not everything owners are reporting.
Reported failure mileage clusters in the 25,000-50,000 mi band — 8 of 11 complaints with an odometer reading on file land there.
Is there a fix? Manufacturer service bulletins
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.
CHRYSLER/DODGE: FUEL SPIT BACK DURING REFUELING. UPDATED 5/14/2012.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
Owners of 2007 Chrysler Aspens consistently describe fuel gushing or spraying back out of the filler neck after the pump's automatic shutoff activates, typically when filling to capacity. The overflow occurs at multiple gas stations regardless of nozzle angle, fill speed, or fuel type, and happens repeatedly—often every fill-up. Fuel shoots out as far as four feet in some reports, splashing onto the person fueling, their clothes, the vehicle exterior, and the ground in quantities ranging from ¼ gallon to ½ gallon or more per incident.
Dealers attribute the problem to a faulty rollover valve or inlet check valve stuck in the open position, requiring fuel tank replacement. Repair costs run $600–$800 for the tank; one owner also paid $1,137 for a failed fuel pump replacement after the overflow persisted. Many owners report dealerships initially deny familiarity with the issue or refuse warranty coverage, sometimes requiring the owner to fill the tank at the dealership to observe the failure before agreeing to diagnose it.
Owners note that Dodge issued a recall (09V003000) for nearly identical overflow problems on Durango and Jeep models but did not extend it to the Aspen, despite the widespread nature of the complaint across forums. A separate secondary issue involves the check engine light and gas cap warning repeatedly reappearing after reset, sometimes traced to fuel tank cracks.
Failures typically manifest between 26,000 and 70,000 miles, with some occurring early in ownership of used vehicles. Owners emphasize the fire and environmental hazards posed by uncontrolled fuel spillage at gas stations.
Same Chrysler Aspen fuel system reports on nearby years: 2008
Failure modes owners describe
Fuel Overflow at Fill-Up (Rollover/Check Valve Failure)
Fuel gushes, spews, or spills back out of the filler neck after the pump's automatic shutoff activates, often in large quantities (up to 1/2 gallon or more). Occurs at the end of filling, regardless of fill rate, nozzle angle, or fuel station, and happens consistently with full fills. Owners report the pump shuts off correctly, but fuel then forcefully exits the tank, splashing onto clothing, skin, ground, and vehicle exterior.
When: Typically at 36,000–70,000 miles; some failures present early (3–4 years old, 26,000–36,000 mi); one case at 27,000 mi; one at 41,000 mi; one at 50,000 mi.
Symptoms owners cite: Fuel spills or shoots back out after pump auto-shutoff; Fuel sprays or splashes onto person, clothing, vehicle, and ground; Occurs every fill-up or nearly every time vehicle is filled to capacity; Fuel shoots out as far as 4 feet away in some cases; Overflow continues regardless of nozzle angle, fill speed, or station; Occurs only when tank is filled past 3/4 full or to capacity; Gas bubbles or burps out of filler reservoir during full fills
Repairs/costs cited: Dealers report faulty rollover valve, inlet check valve failure, or fuel tank replacement required. Repair cost cited: $600–$800 for new fuel tank; one owner paid $1,137.34 for fuel pump replacement after gushing persisted, plus $178.17 for EVAP ECIM switch. One owner reported dealer replaced rollover valve in December 2009, but problem recurred months later.
Recalls/TSBs owners mention: Dodge issued a recall (NHTSA Campaign ID 09V003000) for similar fuel system overflow on certain Durango and Jeep models, but 2007 Aspen owners report the Aspen was not included in this recall. Dealers often deny knowledge of the problem, refuse warranty coverage, and require full tank demonstration or vehicle inspection before diagnosis. Chrysler/Fiat reportedly will not provide assistance or recalls for Aspen owners experiencing this issue.
Check Engine Light / Gas Cap Warning with Fuel Tank Leak
Check engine light and 'gas cap' warning appear on dashboard and repeatedly return after reset, despite gas cap replacement with OEM part. Dealer eventually diagnoses a crack in the fuel tank causing fuel leakage, which triggers the warning codes.
When: One case at 43,000 miles; appears to develop over time with repeated warning resets.
Symptoms owners cite: Check engine light illuminates; Gas cap warning message appears; Warnings return 2–3 days after computer reset or dealership code reset; Fuel tank crack diagnosed by dealer
Repairs/costs cited: Dealer replaced gas cap (OEM Chrysler part), reset computer codes multiple times. Dealer then diagnosed fuel tank crack and quoted $780 for tank replacement. Owner unable to afford repair due to unemployment.
Synthesized from 64 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 12 most recent
Every time I fill up my gas tank the gas pump shuts off normally but when I remove the gas nozzle from my tank a huge amount of gas comes spewing out and sprays the side of my truck as well as the gas pump. It sometimes sprays out as much as four feet away. This is a major fire hazard as well as safety hazard for me and anyone pumping gas in there own cars at the pump across from me. I have been…
Tl*the contact owns a 2007 Chrysler aspen. The contact stated that while adding gasoline to her fuel tank the gasoline would spill back out. The vehicle was not inspected by a dealer nor had the vehicle been repaired. The failure mileage was approximately 41,000. Updated 12/14/2011 *cn updated 05/23/11
I have an 2007 Chrysler aspen with 41,000 miles on it. We bought it three months ago and I've had a problem filling the vehicle with fuel everytime. On several attempts to fill the gas tank, after the automatic shut off in the fuel nozzle trips, a very large amount of fuel will come flying back out. The fuel splashes back out on to me, the fuel hose and all over the car. I have tried several…
Fuel overflows from gas tank on 2007 Chrysler aspen, after station pump auto shuts off. This occurs 100% of the time at any gas station. Problem is not yet corrected, appointment with dealer this weekend. This has occurred for roughly the past 2-3 months. *tr
When I was filling my gas tank gas started to dump all over the ground. There is an issue with the tank! *tr
Due to a defective valve in gas tank that is supposed to keep tank from exploding during rollovers, approximately 1/2 gallon of gas gushes out of vehicle during fill up which goes down vehicle and all over person fueling. This is a 2007 Chrysler aspen. Very dangerous and could cause potential harm or even death. *tr
Tl*the contact owns 2007 Chrysler aspen. While parked and being fueled, the fuel tank overflowed while being filled instead of shutting the pump off. The vehicle was taken to the dealer where the technician stated the fuel tank and gas line need to be replaced. The approximate failure mileage was 27,000.
Every time I fill up my gas tank the gas pump shuts off normally but when I remove the gas nozzle from my tank a huge amount of gas comes spewing out and sprays the side of my truck as well as the gas pump. It sometimes sprays out as much as four feet away. This is a major fire hazard as well as safety hazard for me, my passengers and anyone pumping gas in there own cars at the pump across from…
In filling the gas tank, as soon as the pump stops a considerable amount of gas comes shooting out of the tank. This even happens if I finish the final few gallons at a very slow pace of gas. This has happened on the last three fill ups and also happened a few times some months ago. *tr
Less than a month after purchasing vehicle the gas tank would projectile vomit gasoline if filled more than 3/4 full. It was taken back to dealership 3 or 4 times with short term fixes but reverts to doing it again. The gasoline amount is significant all down the side of the vehicle, all over my clothes, and all over the ground. *tr
Had fuel system trouble with your 2007 Chrysler Aspen?
File a complaint with NHTSA → It's free, official, and how every report above got here — owner filings are the federal safety record this page is built on.
Common questions
How serious is the fuel system problem on the 2007 Chrysler Aspen?
It's a documented issue but not catastrophic. 64 complaints have been filed. Repairs average $1,200 and most owners catch it before it causes a breakdown.
At what mileage does the fuel system typically fail?
Across the 58 complaints that reported odometer mileage, most fuel system failures cluster between 35,000 and 63,000 miles, with the median around 47,000. A quarter of owners report trouble before 35,000; a quarter make it past 63,000. Maintenance history matters more than the odometer alone — this is the reported failure window, not a guarantee.
What does it cost to fix?
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.
Are there any recalls related to fuel system?
No active recalls currently cover fuel system issues on this vehicle. The complaints filed represent owner-reported failures that haven't risen to the level of a manufacturer-issued recall — but they're still worth knowing about before you buy or budget for repairs.
Related
Complaint and recall data sourced from the National Highway Traffic Safety Administration (NHTSA)
public records database. Verify the raw federal record at
nhtsa.gov/vehicle/2007/Chrysler/Aspen.
Severity ratings are derived from reported crashes, fires, injuries, and fatalities. Repair cost estimates are
independent-shop national averages and may differ in your area. Some links on this page are affiliate links.