Constant shut off When fueling

Thank you very much for the reply; I greatly appreciate the help.

I have traced the hose back from the canister, and it seems to connect to a cylindrical item next to the fuel pump. I’m not sure what this part is called, but I’ve seen a number of variations of this component depending upon the size of the tank with a given Ram model. Can you identify this item?

I’ve included a photo of this item below. There are three hoses connected. Two go to valves at either end of the tank and one of the hoses appears to be the line connecting to the canister. I’m guessing this mystery item is not serviceable (as you implied with the possibility of replacing the tank on the whole).

Ultimately, it would be great to confirm this is the point where I need to disconnect the hose to continue with the TSB troubleshooting procedure. If that cures the problem, I’m probably replacing the tank. If not, I’m hoping it’s the old canister (cheaper and easy to replace).

Thanks again!

- Dave

As luck would have it, I was able to find the answer to my recent question in another post:

https://www.2carpros.com/questions/2003-dodge-ram-fuel-pressure

It looks like the "mystery item" is a Liquid Expansion Chamber (per the diagram cited in that post and attached below). I've looked through Chapter 14 (Fuel System) of the service manual, and I don't have that Fuel Delivery Components diagram. It's unfortunate as this diagram matches my Ram 2500's configuration exactly.

Unfortunately, my service manual also doesn't mention this Liquid Expansion Chamber. I've also looked in Chapter 25 (Emissions Control), and that comes up short as well. If anyone is familiar with this diagram and can tell me where it came from, I'd love to get that documentation.

This diagram shows the EVAP Line Connection as well, so now I know where to disconnect and continue working through the TSB. Again, I really wish the TSB had this diagram as well, but better lucky than lost. I will take that next step and report back my findings.

Thanks again for the assistance!

- Dave

A quick follow-up: Â I disconnected the EVAP tube at the fuel tank side, and I attempted to fuel up. Â The issue persisted and the pump clicked off quickly after start. Â Per the TSB, this would indicate a Fuel Tank Replacement is required. Â Needless to say, I'm disappointed about this, and I would appreciate if anyone had any suggestions for further diagnosis or repair. Â

Otherwise, I have to source a fuel tank and, as I understand, these have been discontinued by Mopar. Â Does anyone have a suggestion on where to look? Â Pick-a-part?

Thanks again.

Thank you again for all of your insight. That saves me a lot of second-guessing.

I didn’t see an attachment on the last post. I’m guessing you meant to add information on the Liquid Expansion Chamber, so please share for future reference.

I will reach out to my local salvage yards in the morning. The West (where I’m located) also helps when looking for parts in good condition.

Again, I really appreciate the assistance. Thank you very much!

- Dave

Apparently, my fuel filler hose had warped on the inside (without any visible signs on the outside). Per recommendation, I pulled the hose out completely and inspected. I have attached photos of both ends for your reference, and you can see the blockages immediately inside.

My guess is that a combination of heat and rot caused the interior layer of the hose to expand and create bubbles throughout the length of the hose. With that type of blockage, the fuel pump would, naturally, sense resistance and shut down.

It was a challenge to find a replacement part. I confirmed with my local Dodge parts department the OEM replacement part had been discontinued. Looking to aftermarket parts, we found a Spectra FNH219 part that fit the 2005 Ram 2500, and using this part number allowed me to find an equivalent. I was able to order this through O'reilly Auto Parts' online site for delivery to the store. (Notably, the counter could not order the item, but the website worked.)

I was saved a time-consuming and, likely, costly repair by doing a simple diagnostic the Technical Service Bulletin could have, totally, recommended. Once again, common sense prevailed, but, honestly, I hadn't thought of it throughout this troubleshooting process. That's why you need a second set of eyes on the project.

Thank you again for the assistance, and I hope this is a help for future visitors.