Replacing Fuel Filler Neck In Ford Mustang Gt: Step-By-Step Guide

If you're experiencing a strong fuel odour or leaking fuel in your Ford Mustang GT, you may need to replace the fuel filler neck. This process can be done in your driveway and will take around 30 minutes. Before attempting this repair, it's important to do your research and make sure you have the necessary tools. You'll need to raise the car, remove the right rear wheel, and disconnect the battery. You'll also need to loosen the tank straps and support the tank with a jack. Be sure to have a new fuel filler neck gasket on hand, as the old one may be damaged or deteriorated. With the right tools and precautions, you can successfully replace the fuel filler neck on your Ford Mustang GT and restore your fuel system to its original condition.

Disconnect the battery

Disconnecting the battery is an important first step when replacing the fuel filler neck on a Ford Mustang GT. This is a safety precaution to prevent any accidents or issues while you work on the car.

To disconnect the battery, first, make sure you have the necessary tools. You will need a 3/8-inch ratchet and an 8mm socket. You may also want to wear gloves for safety.

Once you have the tools, locate the battery. It is usually in the engine bay, on the passenger side of the car. Look for the negative (-) terminal, which is usually marked in black. If you cannot find it, refer to your car's manual for the exact location.

Place the ratchet on the 8mm socket and loosen the nut that secures the negative battery cable. You may need to wiggle the cable free. Be careful not to let the cable touch any metal parts of the car, as this could cause a short circuit.

Now that the battery is disconnected, you can proceed with the rest of the steps to replace the fuel filler neck. It is recommended to refer to a detailed guide for this process, as it involves multiple steps and safety precautions.

Remember to reconnect the battery once you have completed the repair work and double-check that the connection is secure.

Loosen tank straps

To loosen the tank straps of your Ford Mustang GT, you will need a 3/8 ratchet, an 8mm, 3/8 drive socket, a long 3/8 drive extension, a T15 Torx bit, a floor jack, and two jack stands.

First, disconnect the battery and raise the car, setting it on jack stands. Next, place a floor jack in the middle of the tank to support the tank. Now, you can undo the tank straps. There are two straps holding your gas tank, each held on by a 13mm bolt. The driver's side strap has the bolt in the front of the tank, while the passenger side strap has it in the back. Loosen them up and take the bolts out. When you do this, your tank is going to drop some, so make sure you have it supported by the jack.

Now, you can slide the filler tube out of the tank. You may have to jerk the tank and tube away from each other to get it out.

Note: Some sources suggest that you may not need to completely undo the tank straps. Loosening them may provide enough clearance to remove the fuel filler tube.

Remove the right-rear wheel

To remove the right-rear wheel as part of the process of replacing a fuel filler neck on a Ford Mustang GT, follow these steps:

First, ensure the car is raised and supported with jack stands. Clean the filler tube and the area surrounding the filler tube gasket. Next, remove the right-rear wheel. Depending on the model year of your Mustang, you may need to remove the passenger-side trunk liner.

Now, you will need to remove the bolts holding the filler tube in place. This will involve removing several 8mm bolts. The number of bolts may vary depending on the model year of your Mustang. For example, one source with instructions for a 1982-1997 Mustang mentions removing four 8mm bolts holding the upper end of the fuel tube to the fuel door cavity.

Additionally, you may need to remove some T15 screws. In the same source for the 1982-1997 Mustang, it is advised to remove two T15 screws and set the fuel door aside, as well as two more T15 screws with rubber stops.

At this point, you should be able to wiggle the filler tube out of the fuel tank. Be careful when removing the tube, as it may require some force, and you don't want to break anything. With the tube removed, you can now proceed to replace the fuel filler neck.

Remove the filler neck gasket

To remove the filler neck gasket, you will need to first make sure your car is raised and supported by jack stands. Next, clean the filler tube and the area surrounding the filler tube gasket. Remove the right rear wheel and the 8mm bolt holding the filler tube in place. Disconnect the battery for safety.

Now, you will need to access the fuel tank. To do this, remove the passenger-side trunk liner and the fuel door. You will need to remove the two T15 screws with rubber stops and two more T15 screws. Then, remove the three 8mm screws inside the fuel door cavity. Separate the rubber vent tube from the plastic housing and wiggle the housing away from the filler tube.

At this point, you should be able to work the fuel filler tube out of the fuel tank. Be careful with this step as you do not want to break the plastic end of the tube. Once the tube is out, carefully remove the rubber gasket from the fuel tank. It may be useful to have a small-handed assistant for this step, as the gasket may fall into the tank.

It is important to note that some people have reported that they had to drop or at least loosen the fuel tank straps to complete this repair. This may be necessary if you are having trouble accessing the filler tube and gasket. Ensure you have a jack in place to support the tank if you choose to do this.

Install the new gasket

To install the new gasket, first, rub a little motor oil on the new gasket to ease installation. Then, place the new gasket on the fuel tank and rub some oil on the inner part of the gasket to ease the installation of the filler tube.

The installation of the filler tube is the reverse of the removal process. First, work the fuel filler tube into the fuel tank. Then, wiggle the plastic housing towards the filler tube and separate the rubber vent tube from the plastic housing. Next, place the fuel door cavity back in, securing it with the 2 T15 screws and 3 8mm screws. Then, secure the upper end of the fuel tube to the fuel door cavity with 4 8mm bolts. After this, reattach the right rear wheel and lower the car from the jack stands.

Finally, reconnect the battery.

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