Fuel tank filler tube replacement

Some tonneau covers include drain hoses to help evacuate water that gets trapped. Installation instructions direct the user to enlarge the factory drain holes for the hoses.

Drivers side drain hole is directly above filler hose. Passenger side is all clear.

I did take the time to peek under there on both sides. I peeled back the fender liner and poked a flashlight in there but didn't quite realize just how close it was. I thought I was being careful and I still fucked it up.

 

ahhhhh that makes sense!

 

***This is my experience doing this job. This is not intended to be instructional or a guide, YMMV, and perform this at your own risk.***

Removed fender line to gain access.




This shot shows the clearance you have to work with between the bed and the frame. If you choose to try to repair your hose without going any further, it's not going to be easy, particularly because the hose has a bellows/flex section right below the drain hole. Presumably this is the spot that is going to be punctured, and it's going to be damn near impossible to accurately repair it without fully removing the hose.




There's a bracket to the left of the filler hose that supports the fender. I removed this to give myself more room to work with.



I also removed this clamp/bracket.



I pushed these little tabs to free the lines.


I removed the collar.

 

Collar removed.



Now with upper portion of hose detached, here's another view of the hose and it's relationship to the bed and frame.


Then I went under the truck to detach the fuel lines that run longitudinally up to the front of the truck. I did this because I would be lowering the tank and did not want to damage any fuel lines.


Once this plastic holder is off, there is access to the bundy style connectors.


Connectors removed.


I went back to the filler hose and disconnected the lines. A little tape to prevent ingress of crud.


Here's a preview of the new filler hose, where it attaches to the tank. I paid special attention to this clip and this junction.

 

****OK, at this point I have the tank lowered a little bit using my floor jack and a long 2x4 to distribute the load. Didn't seem like I needed to take pics of this process, i'm sure anyone could figure it out. One thing I kept in mind was to lower the tank very cautiously there are some connections, wiring for the fuel pump etc up top that are pretty damn near impossible to see. Don't want to hurt those.****

I'm studying the new hose to figure out how to remove it.The grey clip locks into place over those tabs. I carefully used a long flathead to get the clip free.


IMPORTANT! The distance between the fuel hose in the fully seated position and the tank. When the new hose went on, there was a point where I thought it was fully seated but it wasn't. I really had to ram that bitch home. It was noticeable once it fully seated. Anyhow I took this pic to reference that distance so I could verify.


I removed the parking brake cable bracket to give myself more room to maneuver when trying to free the aforementioned clip.


Original hose is off. I found the puncture, very teeny tiny, but it's there. I had attempted to throw some Toyota FIPG 103 on there a week or so ago to temp patch it, but again with the minimal clearance and visibility and the non-smooth surface of the hose, I was not successful.


New hose is on, fully seated. Just needed to push the clip into place, which I did.



And there it is. Just got to put everything back together now.

 

I’m in the process of the same repair for the same reason but I can’t figure out how to disengage the yellow fitting connecting the skinny vent tube to the fuel tank. Can someone PLEASE enlighten me?!?

 

Hey, I don't really remember that at all. If I had an issue with it I would have highlighted it. Not to be a dick, just trying to give perspective. Maybe yours is just being particularly stubborn.

I want to say it was just a cover?

Good luck, patience is key, I usually start breaking shit when I lose my patience.

 

After fiddling with it trying to get it to release for about 30 mins, I decided to post here and wait until morning. I was getting frustrated and, as you said, better to wait. Noticed the same yellow connector in your photos so I was hoping you’d remember the trick to get it to release. I’m able to get the top half of it to slide up but even then I can’t get the metal tube to slide out of what feels like a corrugated rubber hose on the other side of that connector going down into the fuel tank. Any chance that jogged your memory at all?

 

I've been racking my brain and I don't remember that thing at all. If something comes to me I'll report back.

 

I did the same on mine. Don’t feel bad it happens.

 

Success! These pliers were the trick to disengaging that yellow connector on the vent tube.

 

Just did the same thing and undertaking the repair this weekend. Was your tank empty when you dropped it? When you disconnected the fuel lines did you have to catch the remaining fuel or is a check valve stopping the fuel from flowing out when it’s disconnected?

 

I only lowered the tank as much as needed for clearance. You shouldn't need to fully remove it, so long as you can support it.
Less fuel the better, obviously easier to manage it. I think I did it with around 1/4 tank.

The amount of fuel that came out of the lines was minimal. I was able to manage it with a rag or two.

 

Great write-up with photo’s, this will undoubtedly be helpful to others in the future, good man!

 

I managed to replace mine without having to lower the fuel tank but I had to enlist the help of a friend with smaller hands to reach in to secure the connection to the fuel tank. It likely would have been easier to just lower the tank.

 

I successfully attempted this today, the write up helped a lot, thanks for putting it together. I was able to do it without dropping my fuel tank, but it wasn’t easy. One thing of note, make sure you have replacement clips on hand for the fender liner, you will 100% break them and probably have to tear them apart to get them out. I had 50 of them on hand I purchased from Amazon.

I’m going to have PTSD for a while every time I touch a drill.

 

Fellas I’m trying to do this repair and I’m at the point where I’m trying to disconnect the fuel fill line from the gas tank. I’ve got the grey clip out but how the heck do take the hose out ? I’m trying my darnest but I can’t get it to disconnect from the tank. Any tips ?

 

Get as much leverage as you can and just pull it up off the tank. Try rotating it as you pull up. It’s pressed on the tank pretty well but I promise it will come off.

 

Okay it feels really in there and I was afraid I might break something but it sounds like I just need to put some muscle to it .

 

I still can't figure out why people don't think of drilling holes from the bottom of the bed instead of the top. Great write up, BTW! I did this same repair on my Ford Mustang for a bad filler neck grommet. Hoping I don't have to do that repair any time soon on any other vehicle.