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#1489108 - 06/03/08 08:36 AM Fuel Leak At Fuel-Fill-Tube-To-Tank Joint
CarMon Offline
Member

Registered: 04/19/08
Posts: 496
Loc: Southwest Florida
97 CV (Aero); 62,000mi; HPP

Filling the fuel tank today I noticed a stream of fuel flowing out of the joint where the fill tube meets the tank.

Is this common, and how hard is it to fix that (I assume some sort of seal needs replacement).

Thanks in advance.
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#1489132 - 06/03/08 09:15 AM Re: Fuel Leak At Fuel-Fill-Tube-To-Tank Joint [Re: CarMon]
Ask_The_Shack Offline
Over the Hill

Registered: 02/26/06
Posts: 4799
Loc: Long Island, NY
I'd say track down exactly where the leak is, and go buck wild with the JB weld.

I had a small vapor leak that a shop smoke-tested to that same tube. It cost me around $300~ to get it fixed.
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#1489632 - 06/03/08 08:17 PM Re: Fuel Leak At Fuel-Fill-Tube-To-Tank Joint [Re: Ask_The_Shack]
CarMon Offline
Member

Registered: 04/19/08
Posts: 496
Loc: Southwest Florida
Good idea; thanks.
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#1489736 - 06/03/08 10:33 PM Re: Fuel Leak At Fuel-Fill-Tube-To-Tank Joint [Re: CarMon]
TrickedVic Offline
Stranger

Registered: 05/20/08
Posts: 2
Loc: Hollywood,FL
i have the same problem with my 04 marauder. let me know how that j/b weld works out for you! thanks.
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#1491100 - 06/05/08 07:37 PM Re: Fuel Leak At Fuel-Fill-Tube-To-Tank Joint [Re: TrickedVic]
CarMon Offline
Member

Registered: 04/19/08
Posts: 496
Loc: Southwest Florida
If possible I'd like to find a replacement seal and do it myself. I'll start calling around soon to find the part (s).
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#1491130 - 06/05/08 08:03 PM Re: Fuel Leak At Fuel-Fill-Tube-To-Tank Joint [Re: CarMon]
Dan The Vic Man Offline
Poobah

Registered: 11/22/03
Posts: 9882
Loc: Coon Rapids MN
The rubber seal that is on the take hole is broken, i acidently broke mine when i did a fuel pump job and i had to drop the tank again to replace the seal, its like $8 from ford, thats if im thinking your problem was the same as mine.
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#1491310 - 06/06/08 12:29 AM Re: Fuel Leak At Fuel-Fill-Tube-To-Tank Joint [Re: Dan The Vic Man]
Ruski Offline
Member

Registered: 03/31/08
Posts: 297
Loc: California
My 01 crown vic got the same thing, i cant fill up more than half a tank or else it will leak, but i came to a conclusion thats its the rubber o ring that goes in between the fuel pump and the tank that is leaking
heres what i need and maybe your the same way
http://www.autozone.com/R,APP1317834/veh...oductDetail.htm
If your leak when you fill up then you have a diffrent problem, if your does not leak untill you reach more than half a tank then you will need to drop the tank, which is not eazy and then remove the fuel pump then you can replace that rubber thing, i have no idea why they go bad, but i know for a fact that mines is craked.
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#1491561 - 06/06/08 11:56 AM Re: Fuel Leak At Fuel-Fill-Tube-To-Tank Joint [Re: CarMon]
BillyRay Offline
Member

Registered: 12/05/02
Posts: 172
I would drop the tank, the filler tube goes a good 8-10 inches inside the tank, it might not be that seal that is leaking.

I had to driop mine 2 months ago when I accidentally drilled a hole in it whiole mounting subs in the tunk. Dropping the tank is easy, getting it back in there is a royal pain in the a$$.

If it isn't empty hook up a hose to the fuel pump out put and hot wire the fuel pump and pump all the gas out. Either pump it into a can or another vehicle, or if you aren't environmentally conscious just pump it on to the ground.

To drop it jack up the rear and put it on jack stands, put a jack under the tank. Follow the instructions to disconnect the wires, fuel lines and filler tube, straps and then it drops right out. If you already have it empty it comes out in about 20-30 minutes.

I would highly recommend getting new tank mounting bolts from Ford to put it back in. I didn't get them and it took me about 5 hours to get those freaking straps on.

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#1494193 - 06/10/08 08:37 AM Re: Fuel Leak At Fuel-Fill-Tube-To-Tank Joint [Re: BillyRay]
CarMon Offline
Member

Registered: 04/19/08
Posts: 496
Loc: Southwest Florida
I nearly filled the tank yesterday again, (about 2 gal shy of "full"), and fuel still streamed out all the way home and in my driveway. "Dollars on the ground."

@Billy
Holy sheis, Pump it into the ground! But I do appreciate the advice on how to get the fuel out of the tank. Is your CV an Aero or Whale? Mine is an Aero and it seems, based on what I can see, that I won't have to drop the tank (I hope) but I am not sure.

I called Ford this morning and the "Filler Neck Seal" is $41.35 Part # F4ZZ9072DA .

Thanks for the advice so far everyone.



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#1495066 - 06/11/08 11:56 AM Re: Fuel Leak At Fuel-Fill-Tube-To-Tank Joint [Re: CarMon]
CarMon Offline
Member

Registered: 04/19/08
Posts: 496
Loc: Southwest Florida
Anybody know where I can get a cheaper "after market" replacement gas filler neck seal equivalent to
Ford part # F4ZZ9072DA?

I can get one from thefordsource.com (Ford deal in the north)$25 + $11 shipping = $36.

Or, I'll just have to bite the bullet on this one.

Also, the service tech. I spoke with at thefordsource.com said the tank will NOT have to be dropped. Just unbolt the filler neck and move it to gain access.

Thanks!
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#1503726 - 06/23/08 08:24 PM Re: Fuel Leak At Fuel-Fill-Tube-To-Tank Joint [Re: CarMon]
CarMon Offline
Member

Registered: 04/19/08
Posts: 496
Loc: Southwest Florida
Update for anyone interested.

I purchased the replacement gas filler neck seal and received it today. Then I installed it.

Here are some pictures of the new seal, and before and after pictures:
Project: Stop Fuel Leak Where Fill Neck Meets Fuel Tank

After inspecting the old seal, it appears to be in excellent shape. Interestingly, it had a thin layer of gray rubbery sealant of some sort on the bottom of it, where the leak was. I am not convinced that the replacement seal I installed today is going to solve the problem. I will fill the fuel tank soon and test. But I believe I will need to find some sort of gas-resistant goop to surround and seal the union between the tank and the outter portion of the new rubber fuel fill neck seal. We'll see.
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#1504048 - 06/24/08 10:16 AM Re: Fuel Leak At Fuel-Fill-Tube-To-Tank Joint [Re: CarMon]
CarMon Offline
Member

Registered: 04/19/08
Posts: 496
Loc: Southwest Florida
Update

I filled the fuel tank as full as possible today, and to my surprise there was no leaking from the new seal whatsoever, even after driving 20 miles.
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#2683655 - 03/18/13 12:27 PM Re: Fuel Leak At Fuel-Fill-Tube-To-Tank Joint [Re: CarMon]
iMotoPilot Offline
Stranger

Registered: 12/20/12
Posts: 5
Loc: Texas
Awesome write up! I just noticed the same leak from my CVPI today. Ordering part today.

Thank you!
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#2686081 - 03/23/13 10:53 PM Re: Fuel Leak At Fuel-Fill-Tube-To-Tank Joint [Re: CarMon]
iMotoPilot Offline
Stranger

Registered: 12/20/12
Posts: 5
Loc: Texas
Just finished my repair on my 2000 CVPI, there was a hard plastic spacer behind hanger of the filler tube before it feeds into the the rubber gasket into the tank. Made it difficult to remove the filler tube so I had to cut it slightly to remove it. Finished the gasket replacement and reinstalled the spacer. Will check in if any issues.
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#2693052 - 04/07/13 11:32 AM Re: Fuel Leak At Fuel-Fill-Tube-To-Tank Joint [Re: CarMon]
iMotoPilot Offline
Stranger

Registered: 12/20/12
Posts: 5
Loc: Texas
Wanted to add that this repair also got rid of the check engine light issue I had. Trouble code pointed towards the gas cap but the tube to tank seal was the culprit. All is well again.
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