When filling up the gas tank of my 2008 Chrysler aspen, at the end of the fill up, gas shoots out of the gas tank. About 7-10 oz shoots out after every fill up. I am not topping off the gas tank, I am just allowing it to stop automatically. Gas shoots out over the vehicle and onto the ground. This is a very dangerous situation that seems to be happening on many Chrysler aspens according to a…
2008 Chrysler Aspen fuel system problems
severe 29 complaints filed with NHTSA · avg repair $1,200 · see fuel system across all vehicles →
Failure mileage
Complaints
29
Recalls
0
Avg fix
$1,200
1fire
1injury
When does it fail?
Of the 29 fuel system complaints filed for the 2008 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.
What stands out
Owners have filed 29 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.
Fuel system accounts for 18% of all owner complaints filed against this vehicle, across 7 categories tracked.
The failure pattern owners describe
Buyer takeaway: Fuel backflow when filling is the dominant issue across 29 complaints—a check valve failure lets gas spray back out when the pump clicks off, soaking owners and creating fire hazard. A few reports mention stalling after full refueling and one fire incident; repairs run $330 to $800+ and Chrysler sidestepped a recall by issuing a service bulletin.
The overwhelming pattern here is fuel spraying backward out of the filler neck when the pump shuts off at capacity—24 of these 29 complaints center on this single failure. Owners describe everything from a small gush (5–7 ounces) to half a gallon shooting 2–3 feet out of the tank, soaking clothes, skin, and vehicle. The spray happens at every gas station and pump type, regardless of weather or pump speed. One owner got drenched in at least half a gallon and called the dealer, who cited TSB 14-001-12 for exactly this defect.
Multiple owners note Chrysler had already issued a recall for the same failure on 2005 Dodge Durango models—same platform—citing a fuel tank filler tube inlet check valve that won't fully close. The root cause is clear: the check valve is stuck or defective.
A handful of complaints also mention the vehicle stalling right after refueling to full capacity, with one owner noting a similar recall exists for the Chrysler 300. One fire report from 2011 attributes flames under the vehicle to flammable liquid, and the owner discovered fuel system complaints online during investigation.
Dealers acknowledge the problem and charge $330 to $800+ for filler assembly or full tank replacement. Chrysler chose a service bulletin over a recall—a choice at least one owner calls "a profound error in judgment."
Same Chrysler Aspen fuel system reports on nearby years: 2007
Failure modes owners describe
Fuel backflow/overflow when tank is full
When the fuel pump nozzle automatically shuts off at the end of refueling, gasoline sprays or gushes back out of the fuel filler neck instead of staying in the tank. The failure appears to be rooted in the fuel tank filler tube inlet check valve not fully closing, allowing pressurized fuel to escape as the pump shuts off.
When: Occurs at any mileage; owners report it happening shortly after purchase or within a few months of ownership. Most common during full-tank refueling; does not occur if filling stops short of capacity.
Symptoms owners cite: Gasoline sprays or gushes out of filler neck when pump nozzle clicks off; Fuel volume ranges from small amount (5-7 oz) to approximately half a gallon per incident; Spray can travel 2-3 feet from tank opening; Occurs at all gas stations and pump types, regardless of pump speed or weather conditions; Happens with or without vapor recovery systems at stations; Can soak person refueling and run down vehicle exterior
Repairs/costs cited: Dealers report filler assembly replacement costs $800. Some cite need for full fuel tank replacement. One owner noted a canister replacement did not resolve the issue before tank replacement was recommended.
Recalls/TSBs owners mention: TSB 14-001-12 issued to address the defect; owners report this was applied as a service bulletin rather than a safety recall. One owner noted Chrysler had issued a similar recall on 2005 Dodge Durango (same vehicle platform) for identical fuel tank filler tube inlet check valve failure.
Stalling immediately after full tank refueling
Vehicle stalls while driving shortly after filling the tank to capacity. One owner references possible connection to NHTSA Action Number PE13016 and notes a similar recall exists for Chrysler 300. Likely related to fuel system venting or overflow issues affecting engine operation.
When: Occurs within a short window after completing a full refueling
Symptoms owners cite: Engine stalls during normal driving after refueling; Stalling occurs during maneuvers such as left-hand turns at intersections; Loss of power steering control when stall occurs; Does not occur if tank is not filled to capacity
Repairs/costs cited: One owner reports dealer knew the problem and fixed it, but charged owner for repair; stated no recall was available for the Aspen despite recall existing for Chrysler 300.
Recalls/TSBs owners mention: Dealer service acknowledged the problem and performed repair at owner's cost; claimed no official recall applied to 2008 Aspen.
Engine fire/fuel leak hazard
One complaint reports a 2008 Aspen caught fire and exploded without warning. Fire originated from under the vehicle; fire department attributed it to flammable liquid/gasoline from engine. No warning signs prior to fire except smoke that was initially mistaken for exhaust. Owner conducted research and found multiple fuel system complaints online.
When: February 10, 2011
Symptoms owners cite: Smoke visible from front of vehicle; Flames visible from under vehicle; No prior warning indicators; Vehicle occupied at time of fire
Unintended acceleration
Vehicle accelerates unintentionally, typically from a dead stop after shifting into drive with brake pedal engaged, or occasionally when slowing before stopping. One complaint noted dealers had no prior experience with or solutions for the problem.
When: Multiple occurrences over time
Symptoms owners cite: Unintended acceleration from dead stop after shifting to drive; Acceleration while slowing down before coming to a stop; Occurs despite brake pedal being depressed
Recalls/TSBs owners mention: Dealer service managers stated no prior experience or solutions available for this problem.
Synthesized from 29 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 4 most recent
For the past several months, our 2008 Chrysler aspen with 37,000 miles has been spilling fuel at the end of each refueling. The pump shuts off as it should, and then fuel spills out. I would estimate that approximately 5-7 ounces of fuel spill out each time this occurs. I did some research, and learned that there was a recall on the fuel tank of the 2005 Dodge durango (same vehicle - ours is…
Every time I fill the fuel tank the vehicle stalls out while driving. I've had the vehicle stall out on me while making a left hand turn at an intersection and lost control of steering. *tr
Massive fuel spit back on my Chrysler aspen. At first it was just a little bit (almost like a sneeze) but now it is vomiting gas at every fill-up. We have used different gas stations...giant & 2 different wawa stations, all with the same result. *tr
Had fuel system trouble with your 2008 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 2008 Chrysler Aspen?
It's a meaningful issue. 29 complaints have been filed and the failure mode causes operational problems for owners. Repairs average $1,200.
At what mileage does the fuel system typically fail?
Across the 23 complaints that reported odometer mileage, most fuel system failures cluster between 36,500 and 55,000 miles, with the median around 42,540. A quarter of owners report trouble before 36,500; a quarter make it past 55,000. 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/2008/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.