Is my fuel filler neck collapsing? Can't put gas in my Ranger (Flareside)

[JoeVR5]

Hi all,

I'm brand new to the forum, and I was wondering if anyone can help me out with a small problem that has turned into a VERY expensive one.

I have a 1997 Ranger Splash, 2wd, 4.0L Ext Cab, 5spd. It has been an AWESOME truck, and I've had it for almost 10 years now.

About a year ago, I started to have a problem filling my truck with gas. I couldn't pump it any faster than about 2 gallons a minute or it would back up and overflow.

I took it to a shop and without even warning me, it wound up costing $600. Apparently, the filler neck on the 97 Ranger splash is a dealer-only part and it is over $350. Holy Cow!!

The problem is, the new super-expensive hose has now made my fuel-filling problem is WORSE! I can't gas up my truck any faster than a gallon or so per minute or else the pump backs up and spills fuel all down the side of my truck. This happens OFTEN. I cannot even set the gas pump on the first notch. It's VERY frustrating.

I looked under the truck, and it really looks like the hose is completely collapsed. I took it back to the shop and they said that all rangers with the flaresides have this problem because there is a sharper angle going into the tank, and you really can't fill it with fuel at a normal rate.

I have trouble believing that because for the last 8 years, I had NO problems filling it with fuel. Now it takes me almost 10 minutes to gas up my truck.

I took it to another shop, and they tried to put a metal sleeve around the collapsed hose, and hose-clamp the sleeve to try and get the rubber hose to open up a little bit, but that didn't work at all.

I'm REALLY frustrated at this problem, because I have to budget serious time for gassing up my truck. I DON'T want to spend another $350.

Had anyone else had any problems like this? Are there any solutions that won't cost me an arm and a leg?

Any help would be GREATLY appreciated. Thanks all!

 

[Jimmeh]

Have you tried filling it with the nozzle upside down?

 

[JoeVR5]

I can't say that I've ever tried to fill it with the nozzle upside down--I can't get it to fit in there properly. ....But I have definitely tried it sideways--on either side--but it doesn't help. The hose looks completely collapsed at the 90-degree bend leading towards the tank

 

[Bray D]

If its the same design as the fleetside hoses, there's an inner hose that the fuel actually flows through. If that inner hose comes off, you're trying to add fuel throught breather hose (the larger one that surrounds the smaller, inner hose). Then there's no breather for the tank, and you can only fill up at a VERY slow rate.

I have a custom fuel filler setup, and I'm fueling into my breather. It sucks. Same symptoms as you. I'm in the process of finding a stock filler hose to fix the problem.

 

[JoeVR5]

Bray D,

Thanks for your perspective on this.

Do you think that my new stock fuel filler neck was installed incorrectly? Should I be taking it apart and trying to re-install it?

I'm just confused because this filler neck assembly was brand new.

 

[Bray D]

Possibly. I would be pissed if I took my truck to a shop, paid 600 dollars for them to fix a problem, and the problem wasn't fixed. I can't believe they're trying to say that Ford's factory filler neck is what's causing the problem. Why would Ford put a vehicle on the market that you can't fill with gas? I think they're screwing you.

If it were me, I'd take my bed off and see what was going on.

 

[JoeVR5]

What is the easiest way to address this issue without a lift?

I have a paved driveway, so I won't be laying in grass or gravel.

Is it easier to lift the bed off and work on it that way? I really don't want to screw anything up here......

 

[LearjetMinako]

What is the easiest way to address this issue without a lift?

I have a paved driveway, so I won't be laying in grass or gravel.

Is it easier to lift the bed off and work on it that way? I really don't want to screw anything up here......

Before you should try anything. If the Ford dealership did the work, return it for repairs. The work they did is covered under warranty.

I have a 96 Ranger flareside bed. I have no problems with filling up. I can sqeeze the nozzle all the way without a spill over.

 

[JoeVR5]

I didn't have the work done at the dealership.

My best friend's cousin is an ASE certified mechanic and has a legit repair shop in my hometown. I was warned by some other relatives that he doesn't always do good work, but he assured me that it would be fine.

I brought it to his shop thinking that it would be an easy fix (hey, how could he possibly screw THIS up?)

Well, I was wrong, and since I already brought my truck back to him once, I don't want to bring it back to him again because he's sort of like family.

I'm really irritated at him, and I'll never bring another car to his shop, but I need to figure out how to handle this fuel filler neck issue......

 

[Mac]

I can't believe they're trying to say that Ford's factory filler neck is what's causing the problem. Why would Ford put a vehicle on the market that you can't fill with gas?

If you had a '05' Mustang GT built in the first nine months, this is the same issue they had. It took a lot of TSB's to finially get it straightened out. It all came down to the issue of the different tolerance between one car and another, leading to a kink in the hose. Even at the same gas station, one pump might work while the next one wouldn't. Any TSB's out there on your problem?

Dave

 

[superdave1984]

Easier to take the bed off. Be warned however, the clips that the bolts screw into break easily and are not cheap to replace. WD-40 or PB Blaster is your friend. The bed is not very heavy and you and a friend can lift it off easily. Don't forget to remove the screw from the filler neck too.

 

[KELLY88]

What is the easiest way to address this issue without a lift?

I have a paved driveway, so I won't be laying in grass or gravel.

Is it easier to lift the bed off and work on it that way? I really don't want to screw anything up here......

You need to get a good look at it. Get a buddy to help and pull the bed off, it's pretty simple. I had this same problem you're describing. My fuel filler neck cracked and had to be replaced. It's not a stepside bed but the problem is the same. Anyway, when I got the new filler neck the bolts at the bed side didn't line up so I twisted the neck until they did. Unfortunately when I did this I twisted and kinked the inner hose that Bray D mentioned. I twisted it almost closed and that made gas flow through at a very slow rate. Pulled the bed off again, took the new filler neck off and took that apart. Got the bolt holes lined up then put the filler neck back together and reinstalled. No more problems. It's possible that your hose has collapsed, a picture would be helpful, but it's also possible that the shop ran into the same problem about the filler neck not lining up so they twisted it to line it up and kinked the inner hose in the process.

 

[JoeVR5]

Hey, thanks guys for the replies! I feel like I have a pretty good idea as to what I'm up against.

.....and the mechanic who I paid to install that hose seems like the kind of guy who would probably just twist the hose to get the bolt holes to line up.

I shoulda figured....

Now, a few questions about BED REMOVAL!

I have a plastic bed-liner as well as a fiberglass tonneau cover. Will this make removing the bed difficult? Could I just lift up the whole box, tonneau cover and all?

How many bolts are there underneath? Are they easy to remove?

If I happen to break one of those clips, where would I be able to buy them?

Thank you all!!

 

[KELLY88]

You can leave the tonneau cover on I suppose though getting rid of as much weight as possible will only help. You'll need to pull the bed liner out, the main bolts are underneath it. Depending on where you live and if the bolts are rusted out or not you will want to soak them with PB Blaster or some type of penetrating lube at least a day beforehand. Mine weren't rusted and came right out with a pry bar. They will be tight, especially if they've never been removed before. They take a T55 torx head bit, available at pretty much any auto part store. Those are the bitch of the job. There's three small bolts where the filler neck attaches to the bed and a tail light harness that needs to be unplugged underneath the bed, probably hidden behind the rear bumper. Also remove the gas cap as the filler neck will stay in place when you pull the bed. After that get your buddy to help you lift it off and get it out of the way. I set mine on a set of sawhorses to make reinstallation easier and not scratch the bottom but being careful and putting a blanket or tarp down on the ground will protect it just as well.

 

[almostclueless]

This kind of bullshit wouldn't be near as much of a problem except for the G_____ed vapor recovery hoses at gas stations that are supposed to reduce pollution from fueling.



Problem is, have you ever seen the raw fuel that sloshes out of the gas pump nozzle when you remove it from your car?

There is NO WAY we're reducing pollution with these nozzles when RAW LIQUID FUEL is pouring out of the gas pump nozzle.....meanwhile, many folks put up with fueling difficulties because of this grand idea by tree hugging jackasses.


Yes, this one fires me up.