Replacing Fuel Tank Filler Neck: Diy Guide For Car Owners

Changing a fuel tank filler neck is a maintenance task that can be performed on vehicles, and there are several options available for purchase. The fuel tank filler neck is the pipe that connects the fuel filler port to the fuel tank. It is an essential component of the fuel system, ensuring that fuel is directed safely into the tank during refuelling. Filler necks can be made from a variety of materials, including plastic, mild steel, and stainless steel, and are available in different heights and diameters to fit specific vehicle models. They can be purchased as part of a kit or as individual components, with some suppliers offering products that are compatible with specific vehicle makes and models.

Fuel filler necks for different vehicles

The fuel filler neck is a formed tubular steel component that connects the fuel filler inlet and the rubber fuel hose on the gas tank of a vehicle. Over time, the fuel filler neck can rust and leak, or the rubber hose can become weather-cracked, leading to fuel leaks. Here is a step-by-step guide on how to replace the fuel filler neck for different vehicles:

Chevrolet Lumina (1998)

First, run the fuel tank to about half full. Jack up the rear of the vehicle and locate the three screws next to the fuel cap. Remove these screws, as well as any small brackets that hold the filler neck to the body near the clamp for the EVAP pipe. The hardest part is removing the clamps that secure the hoses, so be sure to have the appropriate tools.

Ford Escort (3rd Gen)

Jack up the car and support it on jack stands, then remove the driver's side rear tire. Remove the three screws at the fuel filler door and the three screws holding the plastic shield inside the fender well. Remove the bolt holding the filler neck bracket to the car, as well as the vent hose and filler hose. Transfer the two small square bolt anchors to the new filler neck and replace everything in reverse order with the new parts.

Chevrolet/GMC Trucks (1988-2000)

The fuel filler neck can be purchased from auto parts stores or dealerships. The procedure for replacing the fuel filler neck involves jacking up the vehicle, removing the fuel filler cap, disconnecting the battery, and raising the vehicle using a floor jack. Remove the mounting screws or bolts attached to the cutaway and detach the fuel filler cap cable from the fuel neck. Locate and lower the fuel tank, disconnecting the harness and vent hose as necessary. Remove the clamp on the rubber hose attaching the fuel filler neck, twist and pull it out, and guide it out of the area. Inspect the rubber hose for cracks and replace if necessary. Clean the harness and connector to the fuel pump, and wipe out the rubber hose on the fuel tank before installing the new fuel filler neck. Reattach the vent hose, raise the fuel tank, and reconnect the harness. Attach the fuel tank straps and raise the fuel tank to align the fuel filler neck with the cutaway. Secure the mounting screws or bolts and attach the fuel filler cap cable.

Ford F-350, F-450, F-550 Super Duty (2005-2007)

This procedure requires a new fuel filler neck, a floor jack, jack stands, and basic tools. Jack up the vehicle and place it on jack stands. Remove the rear wheels and the plastic inner fender liner. Disconnect the filler neck from the rubber hose by twisting and pulling it out. Install the new fuel filler neck by twisting it into the rubber hose and securing it with a new clamp. Ensure that all connections are tight to prevent fuel leaks.

Threaded fuel filler necks

• 3" Tall Mild Steel Threaded Fuel Bung
• 3" Tall Stainless Steel Fuel Bung
• 1.25" Tall Bung with a 1" ID
• 2-1/4" OD x 3" Tall Fuel Filler Bung w/ Vent Fitting

In addition to the above options, Tanks, Inc. also offers a flanged fuel neck with a threaded neck. This product can be purchased alongside a Billet Aluminum Fuel Cap CC.

If you are considering purchasing a threaded fuel filler neck, it is important to ensure that you select the correct size and material for your specific vehicle and fuel tank setup.

Fuel filler hoses

When choosing a fuel filler hose, it's important to consider the specific requirements of your vehicle. They come in different sizes and configurations to suit different models. For example, straight rubber fuel connection hoses are available in sizes like GH-2 (2" ID, 6" Long), GH-2.25 (2-1/4" ID, 6" Long), GH1520 (1-1/2" ID x 2" ID, 7-3/4" Long), and GH2225 (2" ID x 2-1/4" ID, 6" Long). Angled fuel hoses and hose reducer couplers are also available for vehicles that require them.

The materials used in fuel filler hoses are designed to handle different types of fuel. For instance, the Gates TPU Polyurethane Belting company manufactures hoses that can handle gasoline, alcohol-extended gasoline, or diesel fuel. This versatility ensures that their products are compatible with a wide range of vehicles.

In addition to the hoses themselves, some suppliers also offer a range of complementary products, such as hose clamps, dry break quick fill kits, dump cans, and remote fill fender kits. These additional items ensure a secure and efficient refuelling process, complementing the function of the fuel filler hose.

Filler neck buckets

The process of changing a fuel tank filler neck involves removing the old neck and installing a new one, ensuring that all components, including the filler neck bucket, are securely connected. This process may vary depending on the vehicle's specific design and the type of fuel tank filler neck being installed.

When purchasing a fuel tank filler neck, it is important to ensure that it is compatible with the specific vehicle's year, make, and model. Additionally, it is crucial to follow the manufacturer's instructions and safety guidelines during the installation process to avoid any potential hazards.

Filler neck grommets

When replacing a fuel tank filler neck, it is crucial to also inspect the grommet for any signs of wear, tearing, or degradation. Over time, grommets can become brittle, cracked, or distorted, compromising the seal and potentially leading to fuel leaks. Therefore, it is recommended to replace the grommet whenever you remove or install a fuel tank filler neck.

Universal fuel filler neck grommets are available in the market, designed to fit a wide range of vehicles. These grommets are self-positioning and self-sealing, accommodating off-centre angular misalignment and axial movement. However, they are not intended to be a fuel-proof seal, so always refer to the manufacturer's instructions and specifications.

When purchasing a filler neck grommet, ensure you acquire the correct size and type for your specific vehicle model. The grommet should fit snugly and securely to maintain an effective seal. Additionally, refer to the manufacturer's guidelines for proper installation techniques and torque specifications to avoid any damage or leaks.

Frequently asked questions