Cant fill gas tank?

Tiny
SJJANSEN
  • MEMBER
  • 2004 DODGE CARAVAN
I keep getting a back pressure overflow when putting in gas. I can run a line all the way down the neck so I know thats not clogged. I had some sputtering when started a few weeks ago and then all of a sudden the problem stopped and was able to fill tank with no problems. Now today it sputtered again when starting and I could only get 1.5 gallons in without it spitting out.
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Saturday, January 3rd, 2009 AT 11:44 AM

18 Replies

Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 108,014 POSTS
Hi:

This happens when the filler neck needs to be replaced because the vent tube is collapsed inside the filler. Here are instructions in the diagrams below to help you fix the problem. Check out the diagrams (Below). Please let us know what happens.
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Saturday, January 3rd, 2009 AT 2:43 PM
Tiny
SJJANSEN
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No that big rubber neck is fine as I replaced as I thought that was the original problem a few weeks ago when it started. I dont know what ball type filler there is as I can shove a 1/4 hose all the way into the tank. The check engine light came on 25 Dec when I started it up (that was the initial studdering) on the way home from church is when I got fuel and it let me fill with no problems. Now the same spudder this morning and again cant put fuel in without it taking me very slowly 10+min. When I do put it in real fast its like a vacumn and it shoots back out with pressure. My brother in law looked the code up and its a air leak code
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Saturday, January 3rd, 2009 AT 5:15 PM
Tiny
JACOBANDNICKOLAS
  • MECHANIC
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Is it an EVAP code?

Joe
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Saturday, January 3rd, 2009 AT 9:19 PM
Tiny
SJJANSEN
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Yes, large or small leak dont remember
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Sunday, January 4th, 2009 AT 10:53 AM
Tiny
JACOBANDNICKOLAS
  • MECHANIC
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Hi:
There is a leak somewhere in the evap system. It could be as simple as a fuel cap or you could look for days trying to find it. They can really be a pain. Check the fuel filler steel down tube for rust problems. If no luck, take it to a shop and have the the system fogged. The fog will leak from the problem area so you can find it. Otherwise, you could be looking for some time. It could even be above the fuel tank which requires you to remove the tank to check.

If it isn't something obvesious, the fog will be the best money you ever spent.
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Sunday, January 4th, 2009 AT 12:12 PM
Tiny
SJJANSEN
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  • 4 POSTS
Thanks, I got the filler neck part and installed it all fixed! Thanks for the suggestion you guys are the best!
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Sunday, January 4th, 2009 AT 4:10 PM
Tiny
PLMBOB
  • MEMBER
  • 2 POSTS
  • 2004 DODGE CARAVAN
  • 6 CYL
  • FWD
  • AUTOMATIC
  • 80,000 MILES
All of a sudden, I can't pump more than a gallon of gas into the tank before the nozzle clicks off. I've removed the fill tube from the tank and noticed a plastic valve in the tank at the neck but it moves in and out freely. Whats's causing my problem?
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Tuesday, March 24th, 2020 AT 2:20 PM (Merged)
Tiny
BLACKOP555
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The plastic valve is a check valve to prevent siphoning of your gas.

O would be checking the check valve on top of the tank for fuel pressure vapors first. Make sure it aint blocked up. That will cause the pressure to build up and keep shutting off the pump.
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Tuesday, March 24th, 2020 AT 2:20 PM (Merged)
Tiny
PLMBOB
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It is mid April and the tank has returned to normal. Is it possible moisture/ice built up at the vent in the tank.
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Tuesday, March 24th, 2020 AT 2:20 PM (Merged)
Tiny
BLACKOP555
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If teh diaphragm is old it could have had a hard time moving all the way in the cold. It is possible that you have moisture in the lines and it caused it to freeze and shut it off like a valve.
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Tuesday, March 24th, 2020 AT 2:20 PM (Merged)
Tiny
HAZCON
  • MEMBER
  • 1 POST
  • 2004 DODGE CARAVAN
  • 123,000 MILES
After replacing the Fuel Pump a few months ago, the tank filled up once without issues. Thereafter, it would allow an average of 2.5 gallons, then its CLICK, CLICK, etc. It takes 10 to 15 min to get nine gallons in the tank.
I replaced the fuel filler neck with a new after market part. Checked for crimped lines/hoses on top of the gas tank, used a vacuum pump to check for obstruction in line between filler neck and control valve on tank. Replaced rubber hose to the tank, used video to check for obstruction in tank. Nothing found. Problem persists.

I am now getting EGR CODES P0405 & P0442. They return when CLEARED. I do not think they are related to issue.

NEED your HELP. It would be GREATLY APPRECIATED. No direct info found on internet pertaining to problem.

Could this be a Charcoal Purge Cannister Problem?
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Tuesday, March 24th, 2020 AT 2:20 PM (Merged)
Tiny
HMAC300
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Check to see if the vent hose is either clogged or pinched. That goes up the filler neck. It may be collapsed inside as well. Unless the flapper valve inside the tank has fomething holding it closed.
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Tuesday, March 24th, 2020 AT 2:20 PM (Merged)
Tiny
GEDWMS
  • MEMBER
  • 2 POSTS
  • 2001 DODGE CARAVAN
  • 165 MILES
My 2001 Dodge Grand Caravan purchased used in 2003 started having a problem with the fuel backing up into the filler neck when fueling. This problem does not happen on a predictable basis, except perhaps more prone to when refueling with a tank that is near half full. At the same time we started experiencing this problem, it seems the fuel gauge began to stay between full and half for a very long time, then when you go below half full, it falls very rapidly, especially the last quarter tank. I don't know if these two things are related. The last two fuelings I had problems both times when trying to fill with the gauge showing one fourth tank. I ran a small garden hose down the filler neck and it was difficult to advance after about one foot. I was able with difficulty to pass it another 18 - 24 inches but never was able to get to the fuel level but was afraid to push too hard in case their was a screen at the top of the tank. Is this a problem on this model that others have had and can you tell me what to do to fix the problem. It is very annoying to try and fill the tank and the backup shuts off the fuel nozzle every few seconds. Thanks for your help.
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Tuesday, March 24th, 2020 AT 2:20 PM (Merged)
Tiny
CJ MEDEVAC
  • MECHANIC
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I'm not real sure how yours is

i need a filler to modify and put on a old willys jeep fuel tank

this one just so happened to be laying in the bed of dodge ram pickup truck (whether it went to the truck, I do nt know)

yours may be sorta like this--upon looking thru "mitchell i" I could not find a diagram of your system

with my super engineering skills, I think the only real reason for a check ball is for "anti slosh" and might also prevent gas from coming out of the gas cap if the vehicle turned over.

I have seen them broken and floating around somewhere in the tank---and no repercussions occurred, still drove fine, with other vehicles

these too might also prevent a "novice siphon-er" from stealing your fuel. But someone could ezily punch this thing on, into your tank. Its sorda a fragile cage around the ball.

What possibly could happen to one like in my pics, is a small hose, stick or foreign object get inserted into it, and broke off when it was snatched out or was small and wedged itself between the ball and the cage

it's also possible that the "seat" or portion of the cage the ball rests in, when fuel pushes it upward after you are finished installing fuel. This part may be worn from the ball bouncing on it over the years, and the ball simply just sticks or lodges into the seat.

If yours is like this, 1st investigate at an auto parts store, can you get just the plastic "check valve assembly" or must you buy the whole filler assembly (napa, autozone, advance auto are some to check out)or is this strictly a stealership item?

The auto salvage yard is yet another option, and I go there often myself

after exploring what you can do or can get and where it's available.I would remove yours and try to determine if you can simply remove missing action figure "darth vader's light saber" from the assembly and all be like new. Or does it need new parts?

As far as the fuel sender, it is most likely unrelated (but you never know)

if you can live with it. Wait until you have fuel pump problems and the tank must come out anyway to replace the pump and the faulty sender

i'm a great example for you (probably not practical for you) I never worry about running out of fuel on either of my two jeeps, my civilian '77 cj 5, as well as my '46 willys army jeep, both have 5 gallon cans on the back, mostly for me. But have helped those stranded too!

Let me know what you find, I hope it's ez!

The medic
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Tuesday, March 24th, 2020 AT 2:20 PM (Merged)
Tiny
SMITHKGB
  • MEMBER
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  • 2000 DODGE CARAVAN
  • 6 CYL
  • 2WD
  • AUTOMATIC
  • 192,000 MILES
Leak at top of gas tank in 2000 dodge caravan. Does the whole tank need replaced or just the tank filler tube?
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Tuesday, March 24th, 2020 AT 2:20 PM (Merged)
Tiny
WRENCHTECH
  • MECHANIC
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That depends on what is leaking and your going to have to determine that. You will probably have to remove the tank to find out. It sounds like the filler neck though
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Tuesday, March 24th, 2020 AT 2:20 PM (Merged)
Tiny
CARADIODOC
  • MECHANIC
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Hi guys. It's common for the pump assembly, actually the rubber gasket, to leak if the huge plastic nut isn't tightened all the way. There's an arrow molded into the tank and one on the nut. If they are not lined up, even by a couple of inches, it won't seal.

Caradiodoc
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Tuesday, March 24th, 2020 AT 2:20 PM (Merged)
Tiny
WRENCHTECH
  • MECHANIC
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As I said, your likely going to have to remove the tank to find out what is leaking. It depends when it leaks the most, during filling, only when the tank is full or only when the engine is running. All would point to different things.
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Tuesday, March 24th, 2020 AT 2:20 PM (Merged)

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