200 Fuel Filler Neck Install

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RuralTruck

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Sep 21, 2020
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Any pics or tips to install the factory fuel filler neck? I have a FSM coming this week, but started and didn’t expect this replacement to be complicated. There must be some trick I’m missing to get the neck in place between the body and frame. Removed the breather box but still doesn’t seem to want to fit through and into place.

Part# 77201-60C40
 
I had some trouble as well. I ended up doing a temporary body lift (loosened all the body mounts). If I recall there are 9 body mount bolts, four on each side and one under the middle row of seats near the carpet joint.

Unfortunately for me I didn't loosed the two at the very rear by the tow crossmember, so I did kind of a funny car lift unknowingly, but it made enough space anyhow. I'll go dig up the post.

 
As an update, I ended up being able to fit it through last night in one last attempt before loosening the body mounts. Took a bit of time to maneuver around. Removed the breather and all of the breather hose clips all the way up to the fuel tank to make more space to move it around. Definitely rubbed off some paint on the neck in the process, but ultimately it worked. It’s an insanely tight fit to get it into position between the frame and body and up in the wheel well.

It certainly would be easier with 0.5-1” extra clearance from removing the body mounts, and perhaps(?) could get away with only the 3 in the back on the passenger side (I’m not certain as I didn’t try), but it is doable without.

Service manager at my local dealer said he’s done one of them, and it’s the worst of any other vehicle he’s worked on. Didn’t really have any insightful tips. Said he would quote 3h for the job (but I’m guessing he also overstated a bit as he just didn’t want me to take him up on it, and he knew I wouldn’t pay that).

Took me less than that, but definitely over an hour between fitting it and then reattaching everything. Would be a bit faster with an extra set of hands.
 
Out of curiosity, why did it need changed? Did you find one of the elusive dual filler necks for an OE subtank?
 
Even less room on the dual filler necks as the main pipe is a bit bigger, and the vent is spaced off a bit more.
Glad it fit in without the body lift, and yeah, loosening the right side rear two and maybe the middle body bolt near the fuel pump would provide enough wiggle room.
 

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