Fuel leak--out of the top of the mayo-jar lid

[Crunch]

Recently I've been noticing that when I fuel up some fuel sprays/spurts out of the top of the mayonnaise jar lid that is on top of the fuel tank. I thought it was the rubber cap on the hose barb that was leaking, and I replaced it. Last night I noticed that it seems to be leaking from several places on the lid itself. So what is involved in replacing the big, white tank lid? It looks like there are only two fuel hose connections and the electrical connection to deal with, but I'm wondering if I will have to replace everything that connects to it and drops into the tank as well, or if I only need to replace the lid and connect everything back together. Anyone know the answer?

 

[rashwor]

My guess is that it is sold as a unit... so the only way you can do it with dodge parts is the whole thing. Also, since you have a pre '05 model ('05 and later come with the in-tank lift pump), they are doing the in-tank lift pumps on those early models; that may complicate it too.

 

[Cosmo]

Is it leaking around the lid, or through various cracks?

There should be a large O-ring between the lid and the tank. Perhaps it's leaking.

 

[AABEN]

You might pull it and put a new gasket if it has one or you could make one for it. Good Luck

 

[Bob4x4]

Is it leaking around the lid, or through various cracks?



There should be a large O-ring between the lid and the tank. Perhaps it's leaking.

No o-ring,there is a seal that fits between the tank unit and tank-it is more of a sleeve.

 

[Crunch]

Is it leaking around the lid, or through various cracks?

It appears to be leaking through the top plane of the lid, on the passenger side of the hose barb, electrical connections and fuel lines. Nothing from around the threads.

 

[Cosmo]

Weird.

My 08 uses an o-ring, apparently they changed the setup.

 

[Crunch]

Weird.



My 08 uses an o-ring, apparently they changed the setup.

Well, after downloading the "Parts Fiche" (https://www.turbodieselregister.com...sions/232223-links-dodge-parts-fiche-pdf.html) and looking up the parts involved I got a better idea on how the top of the tanks is designed. Once I realized the threaded piece is more like the screw-on top of a Mason jar and not a mayonnaise jar lid I crawled under the truck and checked to see if it was still tight. It had loosened ever so slightly, which was enough to cause fuel to leak out around the O-ring and between the two parts of the lid. Tightening it no more than an inch was enough to stop the leak. Thanks for the replies, and thanks for the link to the parts fiche.

 

[dresslered]

Crunch,

Hopefully, you just solved my problem on my '01. Everytime I fill up and top off, fuel spills from the top of the tank and onto the ground. Last fill-up, a concerned customer nearly called the Haz Mat on me.

 

[Prairie Dog]

Can you just tighten down the jar lid a bit? On my 93 the lid was actually a collar that turned around the fixed center section. I was able to just reach up and tighten it and stop all the leakage.

 

[dresslered]

That was it! I was able to turn the jar lid a bit, but I think the final fix will be to find a strap wrench to get it a bit more snug. It is a kind of hard to get the leverage needed on top of the tank.

 

[Crunch]

Can you just tighten down the jar lid a bit? On my 93 the lid was actually a collar that turned around the fixed center section. I was able to just reach up and tighten it and stop all the leakage.

That was it! I was able to turn the jar lid a bit, but I think the final fix will be to find a strap wrench to get it a bit more snug. It is a kind of hard to get the leverage needed on top of the tank.

Yes, that's exactly what I did. Before looking at the parts fiche I thought it was a one piece assembly and the top was all lid. After looking at the parts fiche I saw that it was a threaded collar, much like a Mason jar canning lid. I don't have a strap wrench, but I was thinking the same thing. Fortunately, hand tightening worked just fine but after the summer heat is gone I might borrow one from a friend and put some more twist on it. I originally thought it was one of the rubber caps that fit the hose barbs on the top, and the dealer gave me some from free. I put them on but still had the same problem. I was concerned that the entire top had degraded and cracked, so I looked up the parts to see what they cost. Then the light bulb clicked on above my head and tightening it turned out to be the solution.

 

[Prairie Dog]

Come to think of it, I think I also used a large flat screwdriver as a chisel and just drove it a bit tighter with a few hits from a hammer.
Glad it worked out for you.

 

[dresslered]

Come to think of it, I think I also used a large flat screwdriver as a chisel and just drove it a bit tighter with a few hits from a hammer.

I understand what you are saying but are you some kind of contortionist that can get both hands up over the tank while chewing gum at the same time???

 

[Prairie Dog]

I understand what you are saying but are you some kind of contortionist that can get both hands up over the tank while chewing gum at the same time???

Well, that was on my first gen and I think it was just a bit more accessible

 

[Crunch]

I understand what you are saying but are you some kind of contortionist that can get both hands up over the tank while chewing gum at the same time???

Since there is a heat shield piece of flashing on the passenger side I positioned myself on the driver's side, just forward of the leaf spring. Then I sat up in a reclining position with my head in the cavity of the side of the bed. Kind of a tight fit, but it worked. If I had a strap wrench I would have used it, but fortunately hand tightening worked... so far.