Any DIY for 97 Legacy GT filler neck replacement?

[dereku]

Just bought a 97 GT with the fuel filler neck leaking. Hear it is really common. Is there a how to on replaceing it?

[anothernord]

Just bought a 97 GT with the fuel filler neck leaking. Hear it is really common. Is there a how to on replaceing it?

Should be moved to Technical;

This forum isn't for questions; if you searched this section, and didn't come up with anything, then there isn't a DIY here. Try getting ahold of a Haynes Manual, I beleive it has instructions on how to replace it. If you figure it out, you can make your own DIY and post it here.

[klix]

it is pretty stright forward, just a real pain...
There are a couple bolts I am leaving out below, but they are obvious and will likely break (i know I didn't put all of those back on, but the pipe was stable with those which I did) they are the first and last (prior to tightening the tank hose clamp) bolts you need to deal with

you need the car on stands with the wheel off.
-remove platic cover (watchout for pounds of sand and rust!)
-lossen the filler to tank hose clamp
-remove the vent and recirculating lines from near the top of the filler neck (it actually comes off with like 3 hoses but only 2 connect from memory)
-make sure all hoses are no-longer attached to neck
-remove gas cap and unscrew the filler neck (3 screws)

Then it is just a matter of budging it out... I ended up cutting ...um breaking... the pipe near the curve that turns the pipe toward the tank (use a no-spark method :wink: like mine perhaps) then used a screw driver and pb-blast to gently pry the tank connector off the pipe all around... then started twisting the pipe back an forth while pulling back until the connector let the pipe go free.

On the new pipe I sprayed the top (top facing, not where the gas cap goes!) and around where the other one rusted out with undercoating and let it dry a bit while I was working on removing the bad one.

To install:
-Rotated the pipe in and around everything
-Slip the pipe into the connector
-Attach the hoses near the filler hole
-Reinstall the 3 screws around the gas cap with the cap "leash", but leav cap off for now.
-Tighten the clamp on the pipe to tank connector

I was afraid of breaking it, but made certain it wasn't moving anywhere by pulling and pushing on the pipe to make sure the clamp was tight enough. With everything snug I then put the gas cap on, and undercoated the rest of the pipe. After the undercoat stuff was dry I put the plastic cover (which I think is the main cause of the rust out) back on just to keep it around.

I am now confident that I will not have to replace this pipe again for another couple decades... :smt015

[Huffer]

Take the plastic shield off. It's not needed, and is the main cause of the rusting out.

Also - if you do choose to reuse it, drill a bunch of 1/4" sized holes in the bottom of it to allow water, dust and salt to drain out.