Fuel System complaints by model year
Which parts fail
Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).
Mileage when the problem started
What owners report
Every time I fill the gas tank, the fuel spills out of the fill tube when it gets full. I have tried putting it in slow but before the nozzle can shut off it blows the fuel back out of the fill tube. This is a substantial amount of fuel which I believe is a serious hazard.
For the last 1-2 years, every time I fill up my gas tank my 2009 Chrysler Aspen will stall repeatedly. When the vehicle stalls, all steering and control of the vehicle is lost. The car will restart after about 30-45 seconds. Once the vehicle has been driven approximately three times after fueling up, the problem stops until the next time I fill up the tank. The issue occurs without fail ever time I fill up my tank. I have had it in the shop a number of times and the problem has not been able to be determined or repaired. There have been no codes when a diagnostic is ran (one time there was a small EVAP. Leak but once the ignition coil was replaced, the code was gone). I have had the ignition coil replaced, spark plugs replaced, evaporation control canister replaced, etc. …
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/)
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. …
Frequently asked questions
Which Chrysler Aspen years have fuel system problems?
By NHTSA complaints, the 2007 (108), 2008 (66) and 2009 (9) model years. Fuel System complaints make up 44% of all complaints for the 2007.
Is there a recall for Chrysler Aspen fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for any Chrysler Aspen model year. A widespread problem may still be covered by an extended warranty or a manufacturer service bulletin, so ask a dealer.
At what mileage do Chrysler Aspen fuel system problems start?
Across all years, half of the complaints with a recorded mileage happened before about 62,000 miles; 37% happened before 50,000 miles.
What part fails most often?
Owners most often name the storage › tank assembly (3 mentions), followed by the storage › tank assembly › filler pipe and cap (2).
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.