Tank Assembly problems of the 2007 Chrysler Aspen

29 problems related to tank assembly have been reported for the 2007 Chrysler Aspen. The most recently reported issues are listed below.

1 Tank Assembly problem

Failure Date: 10/27/2013

Just purchased this vehicle used and at first fuel fill-up gas spewed out of tank at end of fill-up. I did not top off, and I was holding gas lever myself. As it shut off, a ton of fuel shot out of the tank all over me. I've read this is a common problem with this vehicle. Why is this not a recall?.

2 Tank Assembly problem

Failure Date: 11/01/2011

Fuel spills out all over during fillup no matter what gas station or how you try to fill it. Pump shut off kicks in but gas still pours out all over the place. It's difficult to even try to stop fueling before the tank fills up. Have tried slowing down the rate of delivery, changing angle of pump. Nothing prevents this. This is a Chrysler problem, not consumer negligence. What's most shocking is that this has been a problem on durango's and Aspen's (similar vehicle) for years and Chrysler still hasn't fixed it. There are posts all over the internet on this. It is a significant safety issue, especially during a rollover (which I have been in once in the past). We have are a family of six and it makes me sick to think my family's safety is in jeopardy with this vehicle. Come on Chrysler - this is nearly a $50,000 vehicle brand new. Stand up and take ownership for your mistake and quit blaming everyone else like fuel manufactures for ethanol etc. Ethanol was in fuel long before this vehicle and fuel system were manufactured. You most likely have a bad supplier - make them pay for it instead of those who are future vehicle buyers.

3 Tank Assembly problem

Failure Date: 11/01/2011

Fuel gushes back out when the vehicle is filled. This problem did not appear until the vehicle was about four years old and had 36,000 miles. I have used multiple gas pumps and it is not fuel station related. Apparently, Chrysler is aware of this as a problem on the Aspen and the Dodge durango, as well as several Jeep models, as there are numerous forums and videos on the internet that show this problem to be widespread. I feel this problem constitutes a fire safety hazard for not only the operator but other service station customers nearby. Research indicates that the problem is caused by an inlet check valve failure in the fuel tank. When I spoke to the dealer, they acted as if they had never heard of this problem in any Chrysler vehicle, but said it might be happening on the Jeep liberty. They refused to order a replacement tank without me bringing the vehicle in and then filling it up with fuel so they could observe the problem. The service rep at the dealer also suggested that after they observed the problem, I should run the tank below half full to facilitate replacement. They said the cost of replacement would be at my expense.

4 Tank Assembly problem

Failure Date: 06/15/2011

Everytime I fill up with gas, the gas pump shuts off and then gas comes spraying out of the fuel tank door.

5 Tank Assembly problem

Failure Date: 03/12/2011

When filling my 2007 Chrysler Aspen I just bought 3/12/11 up with gas, the gas pump shuts off as it should when tank is full, then all of a sudden gas comes pouring back out. Tried three different gas stations still same result. Potential fire hazard and or explosion.

6 Tank Assembly problem

Failure Date: 03/01/2011

The contact owns a 2007 Chrysler Aspen. While attempting to add fuel to the vehicle the contact noticed that gasoline would spill onto his clothing. The failure was similar to NHTSA campaign id number:09v003000 (fuel system, gasoline:storage:tank assembly). The dealer advised the contact that his vehicle was not included in the recall. The manufacturer registered a complaint for the contact and advised him to take the vehicle to a local dealer. The current and failure mileage was 57,000.

7 Tank Assembly problem

Failure Date: 02/26/2011

The contact owns a 2007 Chrysler Aspen 4x4. The contact stated that whenever dispensing fuel into the fuel tank to the full capacity, fuel would spew out of the filler neck and onto the ground. The vehicle was taken to an authorized dealer where they informed the contact that there was a faulty check valve that would need replacing. The vehicle was not repaired. The failure mileage was approximately 63,000.

8 Tank Assembly problem

Failure Date: 02/01/2011

Gas is spewed back out of the gas tank at the end of filling it up, soaking side of vehicle and anyone standing directly in front of it. Dangerous! occurs everytime gas tank is filled up completely full. Nothing has been done- Chrysler will not fix.

9 Tank Assembly problem

Failure Date: 01/22/2011

Purchased 2007 Chrysler Aspen at a local dealer in Jan , have had vehicle 3 weeks and now in shop due to gasoline spillage when filling tank. All 3 times filled the tank gas splashed back all over my clothes and all over the ground. Now the dealership is making me pay for a gas tank. When I purchased the vehicle ,I purchased over $3000 of warranties and was told the vehicle was covered from front to back and top to bottom and now I am informed the tank is not covered . The tanks will cost me $800. 00 and I dont think I should have to pay for this when it was a default . It looks like there has been many complaints for this happening and they should have been aware of this. This is probably one of the reasons the previous owners turned the vehicle back in for a trade. I was told I could if I did not want to pay for the tank , I could consider never topping off the gas tank, yeah right! I have not had to make my first payment yet on the vehicle until Feb 22,2011. I really think I have been given a dirty deal.

10 Tank Assembly problem

Failure Date: 12/16/2010

Everytime I feel up the gas tank it spews out gas all over the place. I have a 2007 Aspen chyrsler.

11 Tank Assembly problem

Failure Date: 12/16/2010

The contact owns a 2007 Chrysler Aspen. The contact stated that the fuel tank would overflow and spill whenever the vehicle was filled past three-fourth of a tank. The contact spoke with the manufacturer and was told that there were no recalls for his year model vehicle. The vehicle was not repaired. The failure mileage was 36,900 and the current mileage was 43,000.

12 Tank Assembly problem

Failure Date: 12/02/2010

Due to a defective valve in gas tank that is supposed to keep tank from exploding during rollovers, approximately 1/2 gallon of gas gushes out of vehicle during fill up which goes down vehicle and all over person fueling. This is a 2007 Chrysler Aspen. Very dangerous and could cause potential harm or even death.

13 Tank Assembly problem

Failure Date: 11/06/2010

After filling fuel tank, when gas pump shuts off, approximately one pint to a quart of gas gushes out of filler tube onto ground.

14 Tank Assembly problem

Failure Date: 11/01/2010

2007 Chrysler Aspen spills gas out at every fill up, unless I stop the nozzle in time. It shoots about 1/2 a gallon of gas back at me. Chrysler wants me to pay $800 for a new tank. Has been doing this for 3-4 months starting around November.

15 Tank Assembly problem

Failure Date: 11/01/2010

Tl-the contact owns a 2007 Chrysler Aspen. The contact stated that while refueling, fuel would spill from the filler neck whenever the tank reached capacity. The failure recurred whenever the vehicle was refueled to capacity. The vehicle was not taken to have the failure diagnosed or repaired. The manufacturer was made aware of the failure. The failure mileage was 36,000 and the current mileage was 43,000. Sm.

16 Tank Assembly problem

Failure Date: 10/31/2010

The contact owns a 2007 Chrysler Aspen 4x2. The contact stated that when refueling the vehicle to almost full, at least one quart of fuel would spill from the fuel tank. The vehicle was purchased used in 2010 and the contact had experienced the failure since purchase. The contact informed the dealer of the failure and the contact was advised that there were no recalls relative to the failure. He then contacted the manufacturer and filed a complaint but no further assistance was offered and the vehicle was not repaired. The approximate failure mileage was 26,000 and the current mileage was 32,000.

17 Tank Assembly problem

Failure Date: 09/14/2010

We recently purchased a 2007 Chrysler Aspen. Everytime we fill up at the pump it does not shut off and sprays fuel everywhere. There is no recall for this model, but they do have the same problem with the same year durango's. All over the internet I have read of this problem and Chrysler says it is a faulty gas tank and needs to be replaced. Mine is not in warranty and I strongly feel that this is a sever safety and fire hazard.

18 Tank Assembly problem

Failure Date: 09/01/2010

The contact owns a 2007 Chrysler Aspen. The contact stated that while adding gasoline to her fuel tank the gasoline would spill back out. The vehicle was not inspected by a dealer nor had the vehicle been repaired. The failure mileage was approximately 41,000. Updated 12/14/2011 updated 05/23/11.

19 Tank Assembly problem

Failure Date: 05/05/2010

Fuel spills out of gas tank when fill up gas tank and pump shuts down. Dealer replaced parts four times. Now the pump shuts down on max, can fill up gas tank only when selecting lower position of pump but it does not spill out anymore.

20 Tank Assembly problem

Failure Date: 01/19/2010

The contact owns a 2007 Chrysler Aspen. She stated that when fueling her vehicle with gasoline she heard a clicking noise and all of the gasoline came back out of the vehicle and leaked all over the ground. The failure occurred every time she filled her vehicle with gasoline. The vehicle was taken to the dealer where it was diagnosed that there was a problem with the check engine valve and that the whole fuel system needed to be replaced. There have been no repairs done to the vehicle. The failure mileage was unknown and the current mileage was 86246. Updated 04/01/10. The dealer replaced the gas tank. Updated 08/18/10.

21 Tank Assembly problem

Failure Date: 01/16/2010

2007 Chrysler Aspen spills gas when filling tank. I have tried stopping the pump before it shuts itself off automatically, but gas still pours down the side of the vehicle and/or shoots back at me. This has now happened five times in a row at different gas stations. This is incredibly dangerous.

22 Tank Assembly problem

Failure Date: 01/07/2010

When filling up my vehicle, gas will spill out of the gas tank (approximately 1/8 gallon). My interior will fill up with gas fumes. This problem is ongoing and happens everytime that I fill up, regardless of how much gas is in my tank before fill up.

23 Tank Assembly problem

Failure Date: 12/30/2009

Fuel overflows from gas tank on 2007 Chrysler Aspen, after station pump auto shuts off. This occurs 100% of the time at any gas station. Problem is not yet corrected, appointment with dealer this weekend. This has occurred for roughly the past 2-3 months.

24 Tank Assembly problem

Failure Date: 12/22/2009

Fuel spills from filler tube every time vehicle is topped off. Happens when tank is filled and pump automatically shuts off. This is a very dangerous hazard. Has happened for last three months.

25 Tank Assembly problem

Failure Date: 12/20/2009

Fuel overflows from gas tank on 2007 Chrysler Aspen, after station pump auto shuts off. This occurs 100% of the time at any gas station. This has occurred for roughly the past 2 months.

26 Tank Assembly problem

Failure Date: 12/15/2009

Severe fuel back splash when filling gas tank.

27 Tank Assembly problem

Failure Date: 11/01/2009

Chrysler Aspen 2007 model gas tank overflows every time I fill up.

28 Tank Assembly problem

Failure Date: 08/01/2009

1. Nothing obvious leading up tp the incident 2. When fueling the vehicle to the point of the auto shut off, the vehicle will burp fuel out of the fill resevoir. At every fill up, it only happenns during full tank fills. We do not keep filling after the auto shut off gets triggered. 3. Dealer says it's a bad check valve inside the fuel tank which is stuck in the open position. A fuel tank replacement is the only option. 4. There is a recall out for very similiar if not identical issue with it's sister truck 2005 Dodge durango. . .

29 Tank Assembly problem

Failure Date: 01/01/2009

2007 Chrysler Aspen gas tank overflows whenever I try to fill it up. . The pump shuts off , but then gas overflows out. I do not top off it just happens with the first shutoff of the gas pump. Gas bubbles out all over truck and ground (and shoes if within reach). This happens 9 out of 10 times if I try to fill it. If I only put in 16-17 gallons we are fine (26 gallon tank). Nothing has been done said they tested it and it is fine. Have seen other posts on the Chrysler forums where other people are having the same issue.


Other Gasoline Fuel System related problems of the 2007 Chrysler Aspen


Fuel Economy of Aspen Vehicles
Aspen Service Bulletins
Aspen Safety Recalls
Aspen Defect Investigations