04 Ram Fuel Issue....wtf Dodge

[kb67mopar]

Alright time for a bit of venting.

So about 2 months ago I stop at the gas station to fill up knowing I need about 20 gallons. Start filling and the pump kicks off after 2 sec. repeat about 4 times...hmm must be the pump. Go to another pump...same crap. pull the nozzle out and try with an air gap and the fuel bubbles up in the filler. (obviously air is not venting properly from the tank). So after some fiddling with it and a few more tries no luck so I take it home and pull off the vent tube at the canister, suck some nasty fumes thru and free up the check valve...take it to the station and vioila...fills like new.

Fast forward 2 months

long story short its happening again. Do some internet searching and find a TSB on the problem...lone behold its common on just about every Chrysler vehicle from 03-08. Some vehicles were lucky enough to have the tank warranted for life because of it (durangos, jeeps, and some Rams)

Me I am SOL. Chrysler in their infinite wisdom molded the check valve into the tank so its not serviceable. So after some talking to the dealer and finding how screwed I am, I find that the tank alone is $507 of which they will help with NONE.

I have since freed the valve in the same manner as last time hoping it will last til warmer weather so i can drill a hole in my tank and put in my own check valve ....Thanks Chrysler!

 

[5.7 hemi]

Chrysler has always cut corners on alot of stuff, but it ends up costing them more in the long run instead of paying an extra nickel at the start. I feel your pain!!

 

[Budnicks]

never heard of that issue before your post... interesting I wonder how common it is ??

 

[moparedtn]

never heard of that issue before your post... interesting I wonder how common it is ??

Ditto - and I've owned (4) late-model Chryslers, including my current '04 Ram and '12 Charger R/T and never heard of such.
I hang out on the most prominent late model Ram website and on places like Allpar.com and never have seen anything, either.

Did have a company-issued Nissan Titan do this to me a lot, though - found out it had an elaborate series of hoses, cannister and purge solenoid up under the bed. Bought a $125 solenoid and all was well again.

 

[kb67mopar]

http://www.ramforumz.com/showthread.php?t=45647

http://dodgeforum.com/forum/3rd-gen-ram-tech/306644-fuel-filling-problem.html

http://www.dodgetalk.com/forums/showthread.php?t=320576

 

[Hemi Rebel]

It's common. " time for a bit of venting" indeed.

 

[kb67mopar]

Ok so I forgot to take photos, and I apologize but I was working toward a deadline. But here is a short description of my solution.

Step one...spend way too much time cramming yourself into weird orientations and get the gas tank out. This involves swearing at the rusty tank strap bolts, special tools to remove the vent lines and breaking the little clip that holds the gas line on and then a little more swearing while trying to get the electrical connector loose because it was happy where it was.

Step two... remove the fuel sending unit and siphon out the remaining fuel...best if you use a hand pump instead of sucking it out...gas tastes bad.

Step three...take your newly purchased "tip over valve" out of its package and measure the size hole you need. (http://www.summitracing.com/parts/bob-90921) This is the one I used...works well.

Step four... drill a hole near the existing vent valve (big white thing that can't be removed. I chose a spot on the backside but still on the hump keeping it high)...pay attention here to make sure that you will not hit the baffle and that the parts sticking up are in a location not to hit anything...the spot I described sits in a hole between the cab and bed. Oh and drill your hole slightly smaller then the threaded portion so you can thread it into the plastic increasing its leak tight capability

Step five...use rtv to seal the top and install the valve and fitting

Step six... drink a beer and relax before you climb back under the truck.

Step seven... use a hack saw blade to cut a portion of the existing vent line out the same length as your new tee. (this line is plastic not rubber) use the large rubber hose you bought at the parts store and cut two pieces big enough to slide over the plastic line and connect to your tee. (you remembered these parts right...if not go get them). Clamp the rubber to the line and Tee (I used zip ties but I also have a gun to tighten them). I also recommend getting good rubber lines not the provided plastic line with the kit.

Step eight... Reinstall the fuel tank...this probably involves you running to the store to buy a little clip you broke on the fuel line since you forgot when you bought the tee and lines..

Step nine... run the hose you already installed on the new tank vent to the new tee and clamp

Step ten... go to the gas station and fill up without it pissing you off.

Step eleven... drink beer and feel proud of saving yourself $461+labor. Cost of parts: $46

If anybody needs to do this I will crawl down there and take a couple photos of where things are and how I did it...but only if requested.