Fuel Tank Filler Neck Seal Replacement.

Discussion in 'Tech Articles, How-To's & Write Ups' started by uncltrvlnmatt, Mar 2, 2007.

  1. uncltrvlnmatt

    uncltrvlnmatt Legend

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    It is not a hard job, but it sucks. Do this with less than half a tank of gas.

    Tools needed, 3/8 drive 10mm socket, 3/8 drive 12mm socket, 1/4 drive 8mm socket, 3/8 extension, 3/8 wratchet, 1/4 extension, 1/4 wratchet, floor jack, 2 jack stands.

    Jack up car and install jack stands (safety first)

    Removal
    Open filler door and remove 3 10mm screws.
    Remove 8mm bolt from clamp mounting bracket on fuel tank to filler neck.
    Remove 4 8mm screws from rubber dust shield at filler neck from underneeth.
    Remove fuel pump connecting plug from mounting clamp.
    Install jack under fuel tank and remove 2 fuel tank strap retainer bolts.
    Lower fuel tank and remove filler neck.
    Remove old seal from fuel tank.

    Installation
    Clean seal area on fuel tank.
    Clean seal area on fuel tank neck.
    Install new seal in fuel tank.
    Install fuel filler neck.
    Jack fuel tank back into place making sure you don't crush any wires.
    Never sieze fuel tank retaining bolts and reattach fuel tank straps. (before fully tightening make sure fuel tank is seated properly)
    Install 3 10mm bolts in fuel neck.
    Install 8mm bolt for filler neck clamp.
    Install 4 8mm screws in rubber dust shield.
    Install fuel pump wiring harness back in mounting clamp.
    Jack up car and remove jack stands.

    You are done go filler-up.
     
  2. ALITL8

    ALITL8 Well-Known Member

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    thanks... had to do this one recently. i guess its not too bad though the original gasket lasted 160K miles :)
     
  3. 1996mustangGT

    1996mustangGT Well-Known Member

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    damn....
    ive been wondering if i was the only one who had this happen,
    thanks this helps out a ton
     
  4. scarface

    scarface Guest

    good write up Matt! I had to wing it when I did it...lol
     
  5. ripper

    ripper Well-Known Member

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    Hmmmm the wifes 95 needs one bad. Dont forget your tools when we go to Gatlinberg Matt. :)
     
  6. DropTopPony

    DropTopPony Administrator Staff Member Admin SN95 Supporter

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    I ripped mine when i changed my fuel pump last month...once you have it apart its easy to swap and next time you drop the tank you won't rip the gasket because you will uderstand how everythig works.
     
  7. 95PGTTech

    95PGTTech Well-Known Member

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    my friend adam just called me with a ripped one...
     
  8. scarface

    scarface Guest

    thats how I ripped mine also.
     
  9. 95PGTTech

    95PGTTech Well-Known Member

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    that's how he ripped his and noticed he was dumping gallons of fuel onto his exhaust on the interstate :rollinglaugh:
     
  10. drrigg

    drrigg New Member

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    Had the same problem on my '98 GT and after the $300 quote from Ford I tackled it myself. But instead of dropping the tank I pulled the filler pipe up into the trunk and, after replacing the seal, simply slid it ack down. Took all of 20 minutes including time to find the screws I dropped in the grass.
     
  11. 1996mustangGT

    1996mustangGT Well-Known Member

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    say what?
    howd you do that?
     
  12. drrigg

    drrigg New Member

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    There is just enough room inside the rear fender to slide the pipe up and, rotating it a little, get it into the trunk. Atleast there is in my car.
     
  13. Javi

    Javi Legend

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    mine got ripped when i took my car to get the exhaust done,next day i went to arlington (about 5.1/2 hours round trip)it cost about $145 round trip at 2.32 the gallon it sucked :'( but here is the part number just in case someone needs it


    F4ZZ*9072*DA
     
  14. ripper

    ripper Well-Known Member

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    LMAO I still havent fixed the wifes. She just doesnt fill it more than half tank. Yea I know im a lazy SOB.
     
  15. 1996mustangGT

    1996mustangGT Well-Known Member

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    im in the same boat :)
    but a crapload of sealer around it and just never fill up
     
  16. LaserRedSVT96

    LaserRedSVT96 New Member

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    good to know i wasnt the only one that had to do this. good thing i have a connection with the parts manager at the local stealership :icon_rr:
     
  17. BigTang

    BigTang Active Member

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    i've never had one rip but i had to replace one when my helper threw it away we i had the tank out to sump it. I'll admit, it did look like trash, but i'll never tell her that.
     
  18. MustangChris

    MustangChris Legend Retired Staff SN95 Supporter

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    i just dropped the tank. it was ony two bolts or so :) lubed up the new gasket, dropped 'er in...
     
  19. Sn95Willis

    Sn95Willis Active Member

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    How do you know if you need to do this???? Prob a dumb ?
     
  20. LaserRedSVT96

    LaserRedSVT96 New Member

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    if its leaking gas out of the passenger side of the tank when its above 1/2 to 3/4 tank. mine spilled gas all over the place. stupid questions are easier to deal with than stupid mistakes :thumbsup: