Fuel filler inlet pipe removal tricks? (2 Viewers)

[Rusty Cruiser]

I am attempting to remove the fuel filler inlet pipe for replacement on my 1995 FZJ80 and was hoping someone could clue me in on any tricks to wiggle it out. I have it freed up at the cap end with the plastic piece held in with four screws removed, I have the two bolts the hold the bracket into the bottom of the body removed, and I have the lower end of the filler and vent tubes loose from the rubber hoses. I have quite a bit of free movement forward and back but can't seem to find the right way exactly to get it to come out. Are there any tricks or am I going to need to lift the body off the frame some? I do also have the tail end of the exhaust removed and the spare tire is out. Having the exhaust out seems to provide a lot of extra room thankfully!

Thanks!

 

[Malleus]

I remember having trouble with this when I replaced the rubber lines on my '95 fuel tank a couple of years ago. I don't remember exactly what I did, but I didn't have to go to any extremes to get it off, or I would have left it in place.

Is this the part you're referring to? 77290-

There is a PITA ring, 77391, that connects the inner and outer "sleeves", 77290 and 77293A

 

[Rusty Cruiser]

I remember having trouble with this when I replaced the rubber lines on my '95 fuel tank a couple of years ago. I don't remember exactly what I did, but I didn't have to go to any extremes to get it off, or I would have left it in place.

Is this the part you're referring to? 77290-
View attachment 3769457

There is a PITA ring, 77391, that connects the inner and outer "sleeves", 77290 and 77293A
View attachment 3769459

No, I have that off. I'm talking about the pipe that goes from there down to the gas tank.

 

[thatcabledude]

As far as I know, you have to lift the body off the frame or get a sawzall out.

 

[Malleus]

That just takes elbow grease. Give it a good pull; it'll come off.

 

[JohnnyUtah2]

I’m pretty sure the tank will need to come down or the body will need to come up.

 

[RC51]

Hi OP, I just did a filler neck replacement on my truck this summer. You have to lift the body off the frame 5 or 6 inches to get it out. Seperating the body from the truck is actually very easy, on a rust free truck its maybe 30 minutes to 1 hour. Instructions for replacing the body mounts here: https://www.energysuspensionparts.com/installation_instructions/energy_suspension/8.4113.pdf

AKA also a good opportunity to replace body mounts.

Once the body is lifted off the frame it takes some wiggling since its a bit of a puzzle, but not hard. Maybe took me about 15 minutes of trying to to wiggle it out and wiggle in. I remeber start with a bend or the tip of the filler and just pushing up on the pipe into different corners to make room for other areas.

 

[Rusty Cruiser]

Hi OP, I just did a filler neck replacement on my truck this summer. You have to lift the body off the frame 5 or 6 inches to get it out. Seperating the body from the truck is actually very easy, on a rust free truck its maybe 30 minutes to 1 hour. Instructions for replacing the body mounts here: https://www.energysuspensionparts.com/installation_instructions/energy_suspension/8.4113.pdf

AKA also a good opportunity to replace body mounts.

Once the body is lifted off the frame it takes some wiggling since its a bit of a puzzle, but not hard. Maybe took me about 15 minutes of trying to to wiggle it out and wiggle in. I remeber start with a bend or the tip of the filler and just pushing up on the pipe into different corners to make room for other areas.

Thank you! Not what I was hoping to hear but glad the hard way still doesn't sound TOO hard! Thanks for the link!

 

[Batameez]

I have no idea how, but my mechanic removed my fuel filler without lifting the body.

 

[Rusty Cruiser]

I have no idea how, but my mechanic removed my fuel filler without lifting the body.

Did he add back a new one? I can easily cut the old one in half to remove it, I more concerned about getting a new one installed in one piece! THX

 

[Broski]

It's been posted before, you have to lift the body or cut the tube.

 

[Mat Jadamec]

2nd on lift the body, it's not that hard. After undoing the body to frame, I used the bottle jack the truck came with against a 4x4 under the body just forward of the rear bumper. I put the jack on a pile of solid concrete pavers.

 

[Irish Reiver]

If you cut the old one off with a grinder the body and frame will separate on their own...

 

[jgaupel]

Hi All, I am about to attempt filler neck removal without body lift. Has there been any update on technique?

Jeremy

 

[Rusty Cruiser]

Hi All, I am about to attempt filler neck removal without body lift. Has there been any update on technique?

Jeremy

I was able to get the old one out without lifting the body but couldn’t get the new one in without loosening the rear 3 pairs of body mounts and lifting the body a few inches. I think it may be possible if you remove the spare tire mounting bracket but not sure that’s much less work than the body mounts unless you’re not planing on putting it back in. Like others said, loosening the body mounts isn’t as bad as I thought it would be.

 

[Kernal]

Here's a link to a video where one person cut the replacement pipe to avoid lifting the body. Most of us on MUD probably would not want to cut
a new pipe in half but there is a method that's not crazy. You have to use a thick rubber hose designed for fuel use and install good clamps on both sides when you connect up the two halves. I would lightly chamfer/clean up the inside and outside ends of the cut pipe to remove any burrs then maybe carefully touch up the cut ends with a fuel resistant coating like POR-15 for fuel tanks and let that cure before assembly.

Warning: don't do any metal cutting (no sparks) under the vehicle while the fuel tank is open or with the pipe still attached to the fuel tank (cover the opening once the old pipe is removed and don't blow yourself up).

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[TurbodreamZ]

I've never had to do it but isn't is possible to get the fuel filler neck out by just dropping the whole fuel tank?

 

[Broski]

I've never had to do it but isn't is possible to get the fuel filler neck out by just dropping the whole fuel tank?

No

 

[Batameez]

I installed a used fuel filler on mine in 2020. The old one was able to come out in one piece, the replacement was cut. I reconnected it using 1.5 inch fuel filler hose from Napa. It was probably made by Gates. It works well enough.