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Fuel smell after adding gas 96 4.0 OHV - NO CEL


sebastian323

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My 1996 4.0L OHV has a slight fuel smell after adding gas. I can smell the gas from the cabin with the windows closed. I currently do not have a CEL on. What are some common areas to check for a fuel leak. My fuel lid is tightened down good (maybe its old and not working?) How dangerous is the situation
 


Uncle Gump

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Fuel filler hose... they deteriorate over time.
 

sgtsandman

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It could be the vent hose as well and possibly the filler neck tube has pin holes.
 

RonD

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+1 ^^^^

Also never overfill gas tanks
When the pump clicks off, that's it, NO MORE
All you will be doing is spilling gas into over flow EVAP tank where it just evatorates, which is what you smell, so a waste of YOUR money
 

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I was getting fuel smell after driving. Truck set for a day and all was fine. Drive to the stop and rob for a beer and smokes and get home it smells like gas. (BII) Investigations found fuel leaking at pinholes on top of tank. Driving around sloshed fuel out. I could see fuel staining the paint on the skid plate. Patched with some JB weld and put rubberized tape on all contact surfaces to prevent rubbing.
 

sebastian323

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I guess when I change the bed I can do the filler neck and any hoses that are readily accessible as well as inspect for leaks on the tank. Ill put rubberized tape on the contact surfaces of the tank as well.
 

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You can try immediately after fueling up looking under the truck at the fill tube to see if there is any wet spots on it. This will happen if the fill tube gets a pin hole in it. IF the hole is big enough fuel can drip on the ground while fueling up.
 

sebastian323

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You can try immediately after fueling up looking under the truck at the fill tube to see if there is any wet spots on it. This will happen if the fill tube gets a pin hole in it. IF the hole is big enough fuel can drip on the ground while fueling up.
Gonna give this a shot.
I am guessing the bed has to come off to replace the fill tube? I think this is the case for the fuel pump as well ?
 

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Gonna give this a shot.
I am guessing the bed has to come off to replace the fill tube? I think this is the case for the fuel pump as well ?
For the fill tube, not necessarily. It depends on the design. There should be a hose between the tank and the tube with clamps.

For the fuel pump, it’s easier to pull the bed than drop the tank and since the tank is held in place, a more solid platform to work.
 

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I had to drop the tank to replace my fill tube. It's not overly hard, it just takes time. I would say a floor jack is a must to support the tank while getting the straps in place.
 

sebastian323

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So I went offroad yesterday, and I could smell fuel after hitting some really large bumps and holes in the road. Does this mean the fuel was spilling out through a leak in the tank as opposed to the filler neck ? I had a 85% full tank when this happened.

What is the compatibility of swapping in a new tank from a newer truck ? Or should I just patch any holes in the tank ?

My truck bed needs replacement anyways so I do not mind working on the fuel system while the bed is off.
 

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Rangers used 2 different size gas tanks
17gal(16.5) in Regular Cab Ranger, shorter wheel base
20gal(19.5) in extended cab or Long Bed Ranger, long wheel base

Filler hoses were also different by year, one hose or two hoses
Single hose looks like this: https://m.media-amazon.com/images/I/61PHyP5m87L.jpg
But its actually 2 hoses, smaller longer hose is where gas goes into the tank, larger outside hose is where air comes OUT while filling the tank
Your 1996 should have this kind, I think 1993 to 1997 Rangers had this type

The 2 hose filler looks like this: https://m.media-amazon.com/images/I/61sOiEznl-L.jpg
It has a separate Vent tube, smaller tube, to let out the air as you fill the tank
So gas tanks with this type of filler would have an extra hole in the top for the Vent connection
So all gas tanks won't be the same, even if they are the same size, they will have different fittings and sizes of openings

And Step Side beds had shorter filler hoses of either type, lol

Smelling gas while you fuel up or when driving is usually cracked/broken filler vent
Can be broken EVAP system hoses, but you should have EVAP Codes come up with either of these things, they should turn on the CEL but not always

Also would set codes if gas tank itself was cracked or leaking

In anycase if you pull back or lift up the bed you should see/smell where the problem is
 

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