Help! Leaking Fuel Filter Cap

[grabinov]

Has Anyone ever heard of a fuel filter cap (the one you remove to replace the filter) working loose and starting to leak? Mine did today. I changed the filter more than 2,100 miles ago, so I know it worked for that period of time. I am running a Fass pump, but have had it on for 15,000 miles.



My wife was in my truck today northbound on the 101 near King City when she called me to say she smelled diesel fuel. She pulled over and found the truck spraying diesel out from under the engine compartment. By this time it was all over the drivetrain, the underside of the truck, and had even smoothly coated the outside of the tailgate! She already had driven 300 miles from home by the time it happened, so it's not like it happened immediately after she started the truck.



A friendly fellow-Dodge-driver (thanks Dave from Salinas) opened the hood and could clearly see that fuel was leaking from area of the the top of the fuel filter assembley. He put his hand on it, but it wouldn't budge in either direction. By this time, I had driven most of the 75 miles to where she was in a borrowed family car, and suggested she just wait for me. Dave didn't know I had hidden the Geno's Fuel Filter socket under my rear seat.



I got the the station, pulled off the fuel filter "canister" cap and checked the o-ring and the cap itself. No cracks, no cuts. I re-installed the cap and o-ring and snugged it down with the wrench. Voila, all fixed. I made it 75 miles back to Grandma's house with no problems at all.



How does this happen? What should I replace? Cap? Gasket? Filter?

 

[Mishkaya]

I have heard of the caps cracking before, but apparently that was not the case with yours... I replaced the plastic fuel filter cap on the '05 with a billet one from Geno's, before I ended up getting rid of it all together when I installed an Airdog lift pump. I am assuming you replace the o-ring every time you change the filter? Seems very strange; maybe it wasn't quite torqued enough and managed to work it's way loose over time...

 

[grabinov]

Seems very strange; maybe it wasn't quite torqued enough and managed to work it's way loose over time...

That's what I was thinking. Does seem strange though. I'm gonna try to get a replacement filter, cap and gasket tomorrow - if anything's open. At least I'll have a spare for the trip home if it happens again. I was thinking about the Geno's cap too.

 

[Motorhead]

If you need anything such as tools ect, I live right off of the 101 in Atascadero, just 10 mi south of Paso Robles. I have fleetguard 7mic filters with O-ring that will fit your truck. PM me and I will give you my phone number. Chris

 

[Radshooter]

Any chance the cap was cross-threaded?

 

[GaryOwen]

I had it happen to me once. Tighhtening didn't help. I replaced the o-ring and re-tightened and all was okay. I suspect the threads were getting worn. I replaced it with the steel billet cover from Geno's and never had another problem.

 

[grabinov]

Thanks all for your help and suggestions. I have actually taken every suggestion above. I took off the cap and checked the o-ring and put it back on - no leaks so far. I also ordered overnight from Geno's a billet cap and replacement filter (since it comes with yet another spare o-ring). And I am about to PM chris with my info in case I get to Paso and have trouble.



Robin at Geno's overnighted me the cap on the Friday between Thanksgiving and the weekend, arranged for a Fedex pickup - not their normal shipper - AND got it to me overnight in California at the end of a gravel road. On Saturday.

 

[Mishkaya]

Thanks all for your help and suggestions. I have actually taken every suggestion above. I took off the cap and checked the o-ring and put it back on - no leaks so far. I also ordered overnight from Geno's a billet cap and replacement filter (since it comes with yet another spare o-ring). And I am about to PM chris with my info in case I get to Paso and have trouble.



Robin at Geno's overnighted me the cap on the Friday between Thanksgiving and the weekend, arranged for a Fedex pickup - not their normal shipper - AND got it to me overnight in California at the end of a gravel road. On Saturday.

You just have to love the service from the fine folks at Geno's! Oo.

 

[DZink24]

i had mine work its way loose a few months ago. i was concerned that it was something more serious, but i set the high idle, got under and looked, and could see fuel bubbles pushing out around the cap. retightened it, been good ever since.