Fuel tank filler tube replacement

It sucks you've all and to deal with this issue. I had the same thing happen a couple years ago when I had mine installed. Luckily, since a shop did the work they also covered the cost of the repair ($485). I hadn't filled the truck with fuel for about a week after the install so when I had gas run everywhere I didn't immediately connect the 2 things. Took it to the dealership as it was under warranty, but of course drilling through your fuel hose isn't covered.

For what it's worth, I posted my experience in a thread at the time and I also make anyone buying or installing a bakflip mx4 or similar tonneau covers aware of this.

 

I’ve got a pair of those pliers, found them under the hood of my wife’s Highlander. I had no clue what they were used for.

 

I know this thread is old, but what part number is the filler hose assembly? I see 77201-04150 in the one picture, but everywhere I put that in it just shows the upper portion. Does that include the lower portion also?

 

77201-04150, is the part I bought. It the fill tube from the fill cap to the gas tank.

 

Thanks. I just bought it yesterday and it is correct, contradicting every parts diagram I could find on the internet.

 

How did you remove collar

 

How do you remove this?

 

I'm Doing mine right now and all I did was remove the bolts on the inner part of plastic around the fill tube and just pulled it out.
without the bolts it's just a rubber seal around the fill tube holding it on.
yours looks a little cruddy - I would put the cap back on and clean it real good first...also yours may be a little stiff by the looks of it.

 

having messed with cars and hospital equipment for nearly two decades...many engineers need a solid punch in the face, imho

 

I'm planning on buying a bakflip. Would using the appropriate sized bit with a stop collar help prevent hitting the tank hose? Looks like it would be difficult to drill up from the bottom if the gas hose is that close to the hole. Is it possible to drill the top side of the box and route the drain hose down under between the box and cab? Thanks. I'd rather not drill the gas hose and have to deal with this. Almost makes me rethink about buying a tonneau with a drain hose. It gets well below freezing here and it will probably get buggered anyway.

 

Thanks Brother.

 

Couldn't you just widen only the passenger side hole and then T the driver's side drain in so both sides drain through one hole? I can't imagine there would be that much water draining that it would be an issue.

 

Why don't you use a sleeve around the drill bit. That way when the composite bed material grabs the bit on the way through the bottom of the bed it will not pull you and your drill deep into the gas filler hose. By sleeve I mean a small tube with an inside diameter of just over the drill diameter set to a length of maybe 3/16" less than the exposed drill bit. Do not use those step drills shown in post #8 in this thread.

 

I just joined the "poked a hole in my filler tube" club and thought I'd share my experience so far. Like everyone else I drilled holes for the tonneau cover drain tubes and i looked at the bottom of the bed before drilling to make sure nothing was directly under. Used a 1/2" paddle bit to drill the holes and unfortunately on the drivers side i pushed a little too hard at the end and it broke through sooner than I thought it would. Looked under the truck and didn't see anything leaking so I thought I was ok. A couple days later I started getting check gas cap messages on the screen and then a day or so later got a check engine light with EVAP code. Was processing it in my mind and figured out I must have put a small hole in the fuel hose. I had not found this post at the time and figured there were two options to replace it, drop the fuel tank or pull the bed. I watched a video on pulling the bed off and it seemed pretty straight forward so i went that route. Took me about an hour to remove the bumper, tail lights, detach the wiring harness from the bed and unscrew the (6) T55 bolts securing the bed. Currently its completely ready to come off and i went to pick up the replacement filler tube this morning but the dealership ordered the wrong part. So looks like I will be working on it tomorrow. After reading how little room there is to work I'm kinda glad I'm removing the bed and it should just be a quick swap and put the bed back on. The bed feels pretty light, I lifted one side of it myself but I'm planning to have a person on each corner just to be safe and then set it on sawhorses while I replace the tube. I'll post more pics when we have the bed off and maybe this will help someone in the future with deciding which route they want.

 

The MX4 is an awesome cover. if i had to do it again, I would maybe pull the rear wheel and the fender well and then put a board or something else under the bed where you are planning to drill. Its not like the hose is right up against bed but the problem i had is that bed is a really tough polymer and took a bit of pressure to get any bite on it. I used a 1/2" paddle bit and at the last little bit it popped through faster than i thought it would and the bit fell through a couple inches and hit the hose.

 

Well. Pulling the bed went pretty smooth. It may have been a little more prep work than dropping the tank but it made replacing the filler tube a piece of cake. That part only took 10 min tops. Bed was light. We set the front of the bed on the rear of the frame and then rear of the bed on sawhorses. Reassembly was as easy as taking a apart. Everything went back together and no more check engine codes

 

Well, I've unfortunately found myself in the same boat as ya'll. I'll be dropping the tank and giving this a go this weekend.

I'll admit I've done a lot of stupid things to my cars in the past but I think this takes the cake. Not because its the worst, far from it...(that goes to cracking an aluminum transmission housing) but because it was such a simple task..."make hole bigger".

To be honest though, everything I've learned by fixing the things I've broken ALMOST makes it worth it.

 

Well I get to replace the fill hose because I was in a rush. Any tips on lowering the tank? Just remove the straps and support with a floor jack? No codes yet but fuel leaks when I try to fill the tank, if I get a code will it reset after awhile once fixed? Thanks

 

The codes I have generated on my truck have all reset by themselves after a period of time or cycles. Your other questions I believe are answered previously in this thread.