Good news from you guys. Drilling a small hole in the cap is looking more attractive all the time. I'd rather not have to drop the tank out to check the top for venting.
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looking at CCOT, this is the gas cap I bought. I noticed they say it fits 71-77. What changed after 77? My FJ40 is 78 so maybe this cap is wrong for it? What was different with regards to the gas tank system between 77 and 78
numby, do you have a photo of the top of that gas cap? thanks
KillerPea: In addition to the above, you've probably got a hole or loose clamp in your fuel lines or maybe the vent line to the canister. Your pressure build-up is not being vented correctly by the canister and has found another way out!