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 2008 Chrysler Aspen owners, lightly cleaned up (personal details are redacted by NHTSA).
When adding fuel, there is a splash back and gasoline spews out and onto who ever is fueling the vehicle. Then when you start the car and drive a few minutes, the car will stall. This vehicle is available for inspection opon request. This issue puts many people in danger. The fueler getting splashed with gasoline, absorbs fuel into their skin, and also the smell of the fumes when entering back into the vehicle. The fueler also now has a very combustible liquid on them. Which is a fire hazard. Also gas spilling is horrible for the enviroment. When stalling, that creates a very hazardous enviroment for everyone in the vehicle, as well as the vehicles around them. A wreck could easily occur because of this issue. The issue has not been inspected by a dealer yet. No warning lamps or messages appeared. And i am uncertain of when the problem began.
When refueling, the gas will overflow after just a few seconds (2-3 gallons of fuel added to empty tank). The fuel handle will shut off and only allow a few ML of fuel to be added to the tank. I must refil tank by holding gas handle and allowing only a trickle of fuel into the tank. Even with this SLOW refil, the fuel often overflows and spills onto the ground (and onto me). This problem began around 120000 miles. This is a continuous, persistent problem. VERY DANGEROUS Internet search indicates that this is a COMMON problem (https://www.chryslerforum.com/forum/chrysler-aspen-41/gas-overflow-fillup-10491/page3/)
After filling the gas tank, the car will stall out randomly without warning. Stalling out will occur for about 25 to 35 miles. After that the stalling out disappears. This has happen while I was turning which made steering difficult. It also has happen when stopping which cause the braking to become difficult.
Tl* the contact owns a 2008 Chrysler Aspen. While driving at various speeds, the contact noticed strong fuel fumes emitting from the vehicle. In addition, the contact stated that the engine warning light illuminated. The vehicle was taken to a dealer who diagnosed that the fuel tank needed to be replaced. The vehicle was not repaired. The contact stated that the check engine warning light had previously illuminated. The vehicle was taken to a dealer who diagnosed that the detector, valve lin and the seal vapor needed to be replaced. The vehicle was repaired. The manufacturer was notified of the failure. The failure mileage was 117,000.
When fueling my 2008 Chrysler Aspen, fuel splashes back out of the fuel tank inlet pipe onto the person putting fuel into the tank. This happens even though you May not be topping off the tank. Fuel splashes onto person, clothes, hands, shoes, vehicle quarter panel and puddles on concrete pad . I have received skin irritation from the contact of the fuel on my hands and have to go in the store to wash my hands or wash them in the dirty water in the windshield scraper holder. I have a couple of friends that own aspens and they have the same problem. In doing research on this issue, I see where Chrysler had a recall on certain durangos and aspens, but according to my dealer, my vehicle and many more were excluded. This is a dangerous issue and needs to be addressed immediately by Chrysler. It is a manufacturers defect and they are responsible. …
2008 Chrysler Aspen stalls for approximately first 5 miles after refueling. MIL illuminates (codes are for p0455 and p0456) then clears by itself after a few days. After researching, I have discovered that the problem is the orvr valve malfunction, this is documented numerous times on many websites throughout the internet. This leads to the EVAP canister malfunctioning (http://opensiuc.lib.siu.edu/cgi/viewcontent.cgi?article=1006&context=auto_pres). This is not only a failure of the emission control system, but also a safety concern since the vehicle stalls, which it always does when slowing or stopping after fill-up. Because the vehicle will lose power steering and power brake ability, I can no longer let my wife or children operate this vehicle as it has become a safety concern. …
Vehicle stalls repeatedly after filling up the fuel tank. The vehicle gives no check engine light or provides any OBD codes to pinpoint the problem. The vehicle stalls both while in motion and when stationary, when in motion all power assist is lost including the power steering and braking assist. My wife refuses to drive the vehicle now after nearly getting into a traffic collision when the vehicle stalled while driving through an intersection and she lost all power assist with our two children in the vehicle. The vehicle will sometimes immediately restart and run for a short period of time then stall again or will just crank and fail to start. This problem only seems to occur after fueling up and topping off the fuel tank. Once the fuel tank burns off some of the fuel it seems to run just fine.
2008 Chrysler Aspen. Consumer writes in regards to vehicle fuel system problems. The consumer stated on February 10, 2011 the vehicle caught on fire and exploded without warning. At the time of the fire, her daughter was waiting in the truck and noticed smoke coming from the front of the vehicle, but assumed it was coming from the exhaust. Then she started to smell something, so she exited the vehicle and saw flames coming from under the vehicle. The consumer stated there was no indication that something was wrong. According to the police and fire report, the fire was attributed to flammable liquid, gas from the engine or burned. The consumer did some research and came across several complaints relating to the fuel system.
Having a problem with the vehicle stalling after refueling with gas. Vehicle will stutter and stall within a couple of minutes. This is dangerous as the stall occurs while driving and you lose steering control of the vehicle. Neither a dealer or private mechanic can get a clear indication as to what is causing the issue. Fuel pump relay(March 2017) and EGR valve(July 2017) have both been replaced and problem is still occurs. Vehicle runs fine after sitting for a while but stalls after refueling. Our vehicle has been in the shop since July 5. We got it back on July 19 and when we put gas in it , it died again and had to be towed back the same night to the shop who had just replaced the EGR valve.
The problem started off with everytime I pump gas and fill the tank, as soon as you remove the pump the gas spews out all over the place. This happened several times at several different gas stations. Suddenly on April 30, 2015 the truck died and would not start. It will cut on and attempt to start but would not stay on. I had the vehicle towed to the dealership and was told that the fuel pump is bad. Funny thing you can't seem to find the fuel pump almost anywhere!!! The Chrysler manufacturer and mopar parts do not have this particular one needed in stock. This seems to be a problem with many of the Chrysler Aspen and the manufacturer should do a recall on this issue!!!
Fuel System complaints in other Aspen years
Frequently asked questions
How common are fuel system problems on the 2008 Chrysler Aspen?
NHTSA has 66 complaints about the fuel & propulsion system of the 2008 Chrysler Aspen, 42% of the model year's 159 complaints. The component named most often is storage › tank assembly (2 mentions).
Is there a recall for 2008 Chrysler Aspen fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for the 2008 Chrysler Aspen, though it has 2 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 2008 Chrysler Aspen fuel system problems start?
Half of the complaints with a recorded mileage happened before about 63,000 miles, and 8% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 2 fires and 2 injuries to fuel & propulsion system problems on this model year. If you notice symptoms, have the car checked before driving further.
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.