Fuel filler tube and emissions test failures

[e21pilot]

For some reason, the fuel filler tubes on some off the early 90's Rangers tend to crack with time. This allows gas fumes to escape and is a common cause of failure for the California smog as the EVAP system has a leak and is not supposed to.

Dropping the tank and replacing the fuel filler tube (and probably the fuel pump for good measure) is the typical fix but I wonder if anyone has a quick and cheap fix that has helped to pass the test? Something like resealing the cracked tube with an outer pipe, even duct tape...?

 

[RonD]

I would find the hole first then see if a patch is possible.

Get a rag and short hose, also a friend.
Engine/key off
Wrap rag around hose, remove gas cap, put hose in filler spout, have friend blow in the hose while holding rag for seal.

You should hear the air escaping.
There are two hoses, the filler hose and the smaller vent hose.

EVAP system can have a few failure points, gas tank venting is just one of them.
And don't forget the gas cap itself, it is part of the EVAP system as well, and can be the source of a failure, but I think Calif. tests those independently.

 

[hank857]

autozone sells both for about the best price. Easiest is to pull the 6 bolts on the bed and lift it. Use a hoist of some sort to raise, I only had wife to assist and only took about hour to raise, replace components and replace bed.

Really if ya dont have a hoist some help from a friend and a 2x4 to hold the front of the bed up would work, just make it a little cramped. Actually 2 2x4s would be better either as a inverted T or in a U configuration so you would not knock it out of position while under there.

 

[wylde8]

Its not a difficult job and not very expensive either. I think I paid about $45 for the hose last time I did this. I would recommend just biting the bullet and getting it done. If your state inspections are like the ones in Missouri, they don't look favorably on any patchwork that has been done.

 

[Revhendo]

This is actually the last thing on my "to do" list to get my truck up and registered. It's way easier to pull the bed and get it done. It allows you to give everything else under the bed a good look also. How often do you get that chance?

 

[4x4junkie]

I tried Black RTV on mine... It worked for one time, but then it failed two years later as the crack progressed.

With the fairly-recent availability of inexpensive aftermarket hoses now, it only makes sense to just replace it.

A word of advice about the new hose:
The aftermarket hoses seem prone to cracking especially quickly (one of mine lasted 1.5 years before I found it looking just like the factory hose did).
Take some high-quality electrical tape (Scotch Super-88, etc.) and thoroughly wrap the outer hose with it (remove the hose clamps so you can wrap under them too, as that's where it tends to crack first). This will prevent ozone and other air pollutants from dry-rotting the rubber and causing it to crack again right away.

 

[97RangerXLT]

Yep, takes about 15 minutes to pull the bed.

You can get a brand new filler hose off of ebay for about 40 bucks. Then entice a friend over with beer/ pizza and yank the bed. 6 bolts, three screws (around the filler neck opening) and a wire harness connector and the bed is off and out of the way, two people can easily remove it.

I did this repair last year, and spent more time removing the bedliner than I did to remove the enitre bed.

while you are at it, you can rust proof and paint the frame. check the spring hangers over while you have the bed off. that would be a great time to address those if you have to. (150 bucks for all four hangers and both shackles, new bolts and bushings from rock auto)

AJ

 

[killj0y]

Yup it's easier and cheaper to just replace it while your in there. Took me about 30 minutes with an overhead winch. 6 bolts plus 3 screws attaching the filler tube to the bed. Bam done. You'll probably spend about half as much on all the stuff to pass emissions and still have to fix it down the road...