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 2005 Jeep Wrangler owners, lightly cleaned up (personal details are redacted by NHTSA).
At every fuel fill up, gasoline splashes back out onto the vehicle, the person filling the vehicle and creates a very unsafe puddle of gasoline on the ground. There is never a time that it does not happen. I would be readily available to make my vehicle available for inspection of this concern. Chrysler has issued recalls for this exact problem on several of their vehicle models all within the same time period of manufacturing. The fuel tank inlet check valve is a widely known and dangerous issue that should be seriously considered to repair the remaining vehicles on the road with this problem. It has been documented by numerous owners of Jeep Wranglers from 2005-2006 while the same issue forced a recall of the same Jeeps in later model years, 2007-2008. The Jeep has been inspected by a certified mechanic where I was notified of much of this information. …
When fueling vehicle tank overflows leaving gasoline on side of vehicle, on self (hands, clothing, shoes, etc.). Not only is this uneconomical, but unsafe, unhealthy, and environmentally unsound. I originally brought my vehicle in for repair in May of 2010, the dealer claimed the evaporation canister was clogged so they replaced the canister and filter for almost $300. Four months later, in October of 2010, I was having the exact same problem and returned to the dealer. They then claimed the roll over valve was stuck in the open position and I now needed a new fuel tank for almost $800. I declined and was charged $100 for their trouble. I now don't ever fill the tank completely. I have found numerous complaints about this problem online in different forums and now here on this website. I do believe Jeep needs to be held responsible for this obviously ongoing problem.
When refueling the vehicle, fuel pump never shuts off. This has been a problem with the vehicle now for a long time. The fuel system allows the pump to continue running after the tank is full. It does not matter what gas station I go to. Gasoline always overflows and spills out onto the ground. I was recently refueling my and the vehicle and the pump did not shut off. A substantial amount of gas flowed out onto the ground and something lit the fuel vapors causing a small fire. I was able to put it out with an extinguisher. This could have caused the entire gas station to catch fire/explode and is extremely dangerous. ..updated 09/12/12 updated 09/12/2012
Like all the other Jeep wranglers mine cannot fill up with gas without the gas overflowing out of the filler neck. This causes pollution, damages the finish of the car as well as a major safety issue. Please make them recall this gas issue as the flapper in the line gets stuck open. At least that is what all the forums seem to say. If you want to see what it looks like just go to youtube --> https://www.youtube.com/results?search_query=Jeep+Wrangler+gas+overflow or put in any other similar search. The majority of the jeeps on the road have this issue.
Every time I fill the vehicle with gasoline, when the pump shuts off a large amount of gasoline 'burps' out and onto the ground. This is due to a faulty check valve installed from the factory that stops working because of the ethanol in the fuel. Jeep has recalled later wranglers for this same issue but left us 2005-2006 owners stuck with the issue. This is a safety, health, and environmental hazard. I will be glad to send you a video of this happening.
Since purchase in November, this vehicle has always shot fuel out of the fuel filler when it reaches a full tank. The gas pump will shut off, but never before it has expelled fuel onto me personally, my shoes, the ground, the filler cap (which is attached to the vehicle by tether), and down the body panel below the filler. This is a serious fire and health hazard for myself and other patrons of the fuel station.
When filling the vehicle with gas it does not automatically stop filling when the tank is full, which results in gas squirting out of the filler. This happens every time I get gas. Getting gas on myself, my clothes, my shoes and down the side of my vehicle is not on my to do list. Jeep/Chrysler should issue a recall or notice to fix this issue. This issue is a fire hazard and is not safe for whomever is pumping gas.
The poor design of the gas tank rollover safety float ball in this vehicle continues to allow gasoline to splash back out of the gas filler neck of the vehicle every single time at an auto shut off fueling nozzle is used. This is a known defect but which they offered a remedy that had an age or mileage limit. This is a gross safety hazard and should warranty t a recall before some one blows up.
Tl* the contact owns a 2005 Jeep Wrangler. While pumping fuel into the vehicle, fuel spewed out. The failure recurred numerous times. The vehicle was taken to a dealer where it was diagnosed that the rollover check valve needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The approximate failure mileage was 54,000. The VIN was unknown.
Tl* the contact owns a 2005 Jeep Wrangler. The contact stated that fuel would spill from the tank each time the vehicle was re-fueled. The failure recurred multiple times. The vehicle was not taken to the dealer. It was diagnosed that the fuel tank needed to be replaced. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was 28,000.
Fuel System complaints in other Wrangler years
Frequently asked questions
How common are fuel system problems on the 2005 Jeep Wrangler?
NHTSA has 448 complaints about the fuel & propulsion system of the 2005 Jeep Wrangler, 69% of the model year's 650 complaints. The component named most often is storage › tank assembly › filler pipe and cap (8 mentions).
Is there a recall for 2005 Jeep Wrangler fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for the 2005 Jeep Wrangler, though it has 1 recall 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 2005 Jeep Wrangler fuel system problems start?
Half of the complaints with a recorded mileage happened before about 50,000 miles, and 13% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 1 fire and 5 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.