Replacing The Roll Over Valve In Your Dodge's Fuel Tank

The rollover valve is an important component of a vehicle's fuel tank, designed to prevent fuel from leaking out in the event of a rollover. While it is generally not necessary to replace the rollover valve regularly, there may be instances when it breaks or becomes damaged and needs to be changed. This paragraph aims to provide an introduction to the topic of changing the rollover valve in a Dodge vehicle's fuel tank, exploring the steps involved in the process and offering insights into potential challenges and solutions.

Troubleshooting a leaking rollover valve

Step 1: Inspect the Rollover Valve

Begin by carefully examining the rollover valve and its surrounding components. Look for any signs of damage, such as cracks, leaks, or loose connections. Pay close attention to the outlet nipple of the rollover valve, as a loose or disconnected hose could be the source of the leak. If you notice any cracks or damage, this could indicate that the rollover valve or related components need to be repaired or replaced.

Step 2: Check for Fuel Leaks

If you suspect a fuel leak, start by checking the fuel filler line and vent hose. Ensure that all hose connections are secure and that there are no signs of leakage. If the hoses appear intact and properly connected, the issue may lie elsewhere.

Step 3: Inspect the Fuel Tank Module

The fuel tank module, which includes the rollover valve, fuel pump, and other components, should be inspected for any signs of damage or leaks. Check the O-ring sealing the fuel tank module; a loose or damaged O-ring could allow fuel to escape. Additionally, look for any signs of fuel leakage around the locknut or other connections.

Step 4: Test the Vent Valve

In some cases, a stuck or malfunctioning vent valve may be the culprit. To test this, remove the vent hose from the valve and attach a short hose to it. Blow and suck on the hose to see if the vent ball clicks back and forth. If it doesn't move, the vent valve may be stuck or faulty. Unfortunately, in some vehicles, the vent valve cannot be replaced, and other solutions, such as installing a longer vent line, may need to be considered.

Step 5: Consult a Mechanic or Specialist

If you are unable to identify the source of the leak or if the required repairs are beyond your comfort level, it is best to consult a professional mechanic or automotive specialist. They will have the expertise and tools to diagnose and resolve the issue. Additionally, they can advise on any necessary parts or repairs, such as replacing the fuel tank or installing a new rollover valve, if needed.

Remember to prioritize safety when working with fuel systems, and always refer to your vehicle's service manual or seek professional assistance if you have any doubts about the troubleshooting or repair process.

Replacing the fuel pump module

To replace the fuel pump module, you will need to first disconnect the power at the battery. Next, remove the fuel filler neck by taking out its three screws and the plastic lanyard for the cap. Push it down inside the bed. Then, remove the tail lights by pulling the wiring and disconnecting the harness from the lights. Push the harness down through the hole and let it hang. Now, remove the spare tire from the bed and take out the rear differential vent hose that is clipped to the bed.

At this point, you will need to unbolt the bed. There are six bolts for a short bed and eight for a long bed. For the front bolts, use an extension and a socket to access them by going between the frame and front leaf spring mount. The rear bolts can be removed straight out of the holes in the bottom of the frame. When doing this step, only remove the driver's side completely. For the passenger side, only remove three-quarters of the bolt, ensuring that there are still at least two full turns remaining so they can hold the pivot.

Now, lift the bed at the fender well and pivot it to the passenger side. Be careful not to lift it too high, as the lower front of the bed will make contact with the back of the cab. You can use a 2x4 or a microfiber towel between the cab and bed to prevent any damage. With the bed pivoted, you will now have access to the fuel pump module. Before removing the module, clean the top of the tank with degreaser and a water hose to remove any debris.

To remove the module, first disconnect the power connector and fuel line. For the power connector, pull out the red tab to release the clip. For the fuel line, use a fuel line disconnect tool to safely disconnect it. With those disconnected, you can now remove the module. There is a retaining ring that holds the module in place. Use a screwdriver and a hammer to knock it counter-clockwise and release the module. Be prepared, as there will be fuel inside the module that will spill out.

With the module removed, you can now install the new one. Place the new module in the tank with the fuel line port facing the driver's side. Secure it with the retaining ring and reconnect the fuel line and power connector. Tug on them gently to ensure they are locked in place. Now, you can lower the bed and bolt it back down, ensuring you do not forget to reconnect the filler tube. Reconnect the battery and turn the key to the "ON" position to prime the pump. Repeat this process a few times to ensure the pump is working correctly. Finally, start the vehicle to verify that the pump is functioning properly.

Locating the correct parts

Start by identifying the exact model and year of your Dodge vehicle. This information is crucial as parts can vary significantly between different models and years. In your case, it seems you have a 1994 or 2000 Dodge Ram, which is a crucial detail to narrow down your search.

Online forums and communities can be a valuable resource. As seen in the DodgeForum.com and DodgeTalk Forum posts, other Dodge owners and enthusiasts often share their experiences, recommendations, and part numbers for specific models. Take advantage of these communities to seek advice and learn from others' trials and errors.

When searching for parts, be as specific as possible. For example, search for "Dodge Ram rollover valve" or "fuel tank rollover valve" to narrow down your results. This will help you find suppliers or retailers that specifically cater to Dodge vehicles and their unique parts.

Consider purchasing from official dealerships or authorized resellers. While they may be pricier, they are more likely to have the correct parts for your Dodge. In your case, the Mopar brand, available on Amazon, seems to be a popular choice for fuel tank rollover valves.

Don't be afraid to ask for help. If you're unsure, contact the dealership or a trusted mechanic. They can guide you in locating the correct parts and may even offer installation services if needed.

Lastly, remember to verify compatibility. Even if you find a part that seems to fit your Dodge, double-check the specifications, model, and year compatibility to ensure it will work with your vehicle. This will save you time, money, and potential headaches down the road.

Good luck with your search, and remember to be patient and diligent in locating the correct parts for your Dodge!

Temporary fixes for a broken rollover valve

A rollover valve is part of a vehicle's EVAP system, which prevents fuel from leaking out in the event of a rollover. While it is not advisable to drive with a faulty rollover valve, there are temporary fixes that can be applied in case of an emergency. Here are some temporary solutions for a broken rollover valve:

• Using Epoxy or JB Weld: If the rollover valve is cracked or broken, a temporary fix is to use epoxy or JB Weld to glue the pieces back together. Clean the surface of the valve and apply the epoxy or JB Weld according to the manufacturer's instructions. This solution is not permanent, but it can buy you some time until you can replace the valve or the fuel tank.
• Tapping on the Fuel Tank: Sometimes, the rollover valve gets stuck closed, preventing air from escaping and not allowing fuel to enter the tank. A temporary solution is to tap on the top of the fuel tank where the rollover valve is located, using an object like a broomstick. This may release the valve and allow you to fill the tank.
• Cleaning the Vent Tube: In some cases, the issue may not be with the rollover valve itself but with a clogged vent tube. Overfilling the tank can cause liquid fuel to enter the vent tube, which can then clog the charcoal canister. Cleaning the vent tube and replacing the charcoal canister may resolve the issue temporarily.
• WD-40 through the Vent Tube: If the rollover valve is stuck, some people have suggested using WD-40. Spraying WD-40 through the vent tube may help to loosen the stuck valve and allow it to function again.

It is important to note that these are temporary fixes and are not long-term solutions. A faulty rollover valve can lead to fuel leaks and other issues, so it is important to replace the valve or the fuel tank as soon as possible. Always refer to a certified mechanic for proper diagnosis and repair.

How to access the fuel tank

To access the fuel tank on a Dodge vehicle, you will need to determine the make and model of your Dodge vehicle, as the process can vary. For some Dodge models, such as the 2001 Durango, there is no access panel to the fuel pump, and the fuel tank must be lowered to access the pump.

• Use a floor jack to support the plate beneath the fuel tank.
• Use a gear wrench or ratchet with a swivel socket and extensions to remove the bolts securing the fuel tank.
• Once the bolts are removed, carefully lower the fuel tank to access the fuel pump.

For other Dodge models, such as the 2nd Gen Ram Truck (1994-2001), it may be possible to access the fuel tank by loosening bolts and jacking up the driver's side of the bed. This method was suggested by a user on DodgeTalk.com, who reported that it was "much easier than dropping the tank".

Additionally, for some Dodge minivans, it may be possible to create an access cut in the floor over the fuel pump, as suggested by a user on Chryslerminivan.net. However, this method is not recommended by all users, as it may create a convenient place for rust to start and for carbon monoxide to enter the vehicle.

If you are unable to access the fuel tank through these methods, you may need to consult a professional mechanic or refer to a model-specific repair manual for further guidance.

Frequently asked questions