Which parts fail
Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2007 Chrysler Aspen owners, lightly cleaned up (personal details are redacted by NHTSA).
My 07 Chrysler aspen has a huge fuel problem and as I have read it's happening to a lot of people! When I fill my car up with fuel no matter what store I am at the gas starts spewing back out of the tank. I do not over fill my car the moment the gas pump clicks that it's done, a lot of gas starts spewing out onto the ground! I believe this is a potential hazardous situation for all involved especially my family! For one I am stressed out about if there were to be an accidental rollover the gas would go everywhere, and 2 when it pours out onto the ground or could even splash out onto my skin I could end up with chemical burns or the bio hazard issue we are having with the gas just being powered onto the ground without me being able to control it! Chrysler doesn't seem to think this is a problem or that it's hazardous! …
When fueling the vehicle as soon as the pump pops off indicating your tank is filled gass will sphew/ or spray back out of the vehicle and onto the person fueling, the side of the vehicle and the ground. This happens every single time no matter what fuel station you use,regardless of the time of day or temperature outside. After looking online I can see there have been numerous reports of this from other 2007 Chrysler Aspen owners going back several years; however, I have not been able to locate anything indicating this is a recall and my vin number indicates all recalls have been addressed on this vehicle. Is there a solution for this issue, is it being repaired by Chrysler or what is being done? Please let me know, as this is a safety issue for anyone fueling up , anyone in the vehicle or around the vehicle. …
When filling the gas tank up using the "fill lock" feature on nearly all modern fuel pump nozzles, when the tank gets full the fill nozzle clicks off and about a half a pint of raw fuel is "purged" back out of the tank filler neck. At first I thought this was a problem at a specific fuel station. I have since learned that it can do it anywhere, at any time of day, and at any temperature.
Aspen has only 16000 miles and has a horrible problem of burping fuel out of the tank when filling up at what ever pressure one holds the nozzle. Every time tank is filled it dumps out 1 to 2 gallons of full on myself and the body of the car as well as on the ground. I have taken it to Chrysler only to be told that a recall has not been issue yet a TSB has been issued by Chrysler them selves acknowledging the problem and the solution for the life of the vehicle. TSB 14-001-12 classifying it as an extended warranty bulletin. Acknowledging that Chrysler is aware of the problem being a stuck flapper in the gas tank. Chrysler is not wanting to resolve the problem in my vehicle saying that they don't have a specific recall noted and that the TSB bulletin is for there own techs and not for customer awareness. …
Every time we fill the gas tank ... The vehicle will stutter / shake when at idle or die completely at idle like at a stop sign or drive through window. It will restart after about 30 seconds. After it has been driven about 25-40 miles it stops happening. We have paid for total vehicle inspections, we have also paid $1300 to have every single problem a certified Chrysler dealership can find fixed. This did not help the problem at all and the dealership says there is absolutely nothing wrong with the SUV. This is the car our son drives and we are very concerned. We are not in a financial position to replace the vehicle and have now emptied our savings to have the vehicle completely serviced, inspected and repaired.
Every time I put gas in to my tank (not topping off) fuel gushes back out of the fuel tank and on to the ground after the gas pump shuts off when the tank gets filled more than 3/4 full. It has happened at numerous different gas stations and has happened when I am holding the handle to the gas pump and when the pumps auto shut-off feature is used. Each time that it has happened a large amount of gas has been spilled on the ground, on the side of the vehicle, on my shoes. On numerous occasions the gas station attendant has had to block off the gas pump and come over and clean up the spill. Each time it has happened the vehicle has been stationary and not running.
I purchased this vehicle in August 2010. It is a 2007 Chrysler Aspen. I had it just a few months and I was having issues with the steering. I am good driver and drove to work each day without issue. I went to my local mechanic and he advised the tie rod needed to be replaced. He has been in business for years and noted how odd it is that a newer vehicle would need a tie rod replacement. He had never seen this before. It cost over $500 to get it replaced. He said had I driven it just a few more days the whole front would have broken causing an accident. I also had an issue in 2012 with a emission sensor and my gas tank.
Tl* the contact owns a 2007 Chrysler Aspen 4x4. The contact stated that it took approximately 20 minutes to fill up her fuel tank due to an inconsistent flow of fuel. The contact attempted to place fuel in her vehicle at several different stations and experienced the same failure each time. Century Dodge Chrysler Jeep Ram (13500 veterans memorial pkwy in wentzville, mo 63385) was notified of the failure and stated that there were no recalls on the vehicle. The manufacture was aware of the issue. The approximate failure mileage was 58,000.
Tl* the contact owns a 2007 Chrysler Aspen. When refueling the vehicle, fuel spewed out of the tank. The vehicle was not diagnosed or repaired. The contact mentioned that the fuel cap was previously replaced, but the failure persisted. The manufacturer was not made aware of the failure. The failure mileage was 105,000. Updated 11/04/15 another dealer offered to fix the vehicle free of charge. Updated 01/16/16. The consumer stated the dealer offered to repair the vehicle free of charge. Updated 2/1/2016
When putting gas in after removing the pump gas comes spraying out all over whoever is filling up the vehicle on the side of my vehicle and on the ground this is a safely issue for everyone in the car the vehicle itself and however is filling the car up as well as the gas station that you are filling up at. It happened today and 1 time before that I have had the vehicle less then a month but see its a common issue and spoken about alot online.
Fuel System complaints in other Aspen years
Frequently asked questions
How common are fuel system problems on the 2007 Chrysler Aspen?
NHTSA has 108 complaints about the fuel & propulsion system of the 2007 Chrysler Aspen, 44% of the model year's 244 complaints. The component named most often is storage › tank assembly (1 mentions).
Is there a recall for 2007 Chrysler Aspen fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for the 2007 Chrysler Aspen, though it has 3 recalls for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2007 Chrysler Aspen fuel system problems start?
Half of the complaints with a recorded mileage happened before about 57,000 miles, and 6% before 25,000 miles.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.