In-tank module leaking after vent kit mod.

[Spooled-up]

I have a customer that just installed the vent kit. He is getting a leak around the in-tank module. He has double checked the fuel lines and they are on correctly and not leaking. I have not personally installed the newer in-tank module and I'm looking for a reason that it would be leaking.



He says that the ring didn't go on with as much tension as it came off with.



The module didn't "pop up" when it was re-installed in the tank like it did when he removed the ring.



Is there a way to install this module and not have it seated correctly?



What could make the module and locking ring not make a good seal at the top of the tank?



Any help would be appreciated.



-Dave

 

[GTani]

Maybe the gasket is not seated properly.

 

[Spooled-up]

Is there a gasket on the newer in-tank modules?

 

[DJennings]

When I did mine, I had to use a mallet and punch to completely turn the ring into the set position. There is an "indent" you have to overcome before it is set completely.



That was the only thing I noticed that was different between the install on my 04. 5 and my 06.

 

[Walker]

Ok guys. Here's the story. After I talked to you David, I continued checking lines etc. and the only thing I can come up with is that it has to be at the retaining ring/ pump module seating. You can't screw up the fuel lines; they either "snap" on and hold or they don't (they were both tight). The electrical connector slides in and locks with the red sliding tab (as stated by the instructions), but this has no way to cause a leak. All hoses (old vent, new vent, and filler hose) are all dry (no cuts or holes).



When I took off the retaining ring, it was real snug and required a hammer and screwdriver to "tap" it loose to release. When I spun the ring off, the pump "jumped" up out of the tank about 3 inches because of the spring loads. When I reinstalled the pump (which only fits in one way) on the tank, I pressed it down (against the spring tension) and it never "sprang back up" like it did when I first unscrewed it. I then placed the retaining ring back on and spun it to the locked position. The ring had a little play after that and never really was "snug", and did not require me to hammer (tap) it back into a tight position. I thought to myself "hmmm, maybe the spring load of the pump has to force itself "up" against the retaining ring to help lock it tight and create a better seal (just a guess). So, I put it all back together and let it go thinking maybe the springs would eventually "pop" back up and seat.



Then for the fill-up. I hit 36 gallons and the fuel spill was on. About 2 gallons come spraying out from under the truck and the "oh . . it" face was on. Raced down the highway a bit to burn off some fuel to get the level down and then back to the garage. Took off the rear wheel. Lowered the tank to the end of the straps. Checked everything out. No leaks at the new vent fitting, hoses, fuel lines, etc. So, it has to be the at the retaining ring.



Here's my question (finally). I don't remember seeing any type of O-ring or gasket. Is it possible I missed it and it fell into the tank somehow? There's nothing on the ground. If so, what color is it (black or maybe clear?) I'm trying to recall any items down in the tank that I might have overlooked. It seems that a gasket would have raised the pump enough to "snug it up" and helped to make the retaining ring go on more tightly.



Ok. The next step is to burn up my $100 new tank of fuel so that I can lower it again and recheck the pump/ring fitting.



BTW. The install went great. No problems (with any of David's product). And I can't wait to get this puppy fixed right so I can "top it off" for real next time. I just might hit $120 this time

 

[nickleinonen]

I don't remember seeing any type of O-ring or gasket. Is it possible I missed it and it fell into the tank somehow?

taken from 2006 service manual:



REMOVAL

1. Drain and remove fuel tank (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL TANK - REMOVAL).

2. Note rotational position of module before attempting removal. An indexing arrow is located on top of module for this purpose.

3. Position Special Tool 9340 (3) into notches on outside edge of lockring (5).

4. Install 1/2 inch drive breaker bar (1) to tool 9340 (3).

5. Rotate breaker bar counterclockwise to remove lockring.

6. Remove lockring. The module will spring up slightly when lockring is removed.

7. Remove module from fuel tank. Be careful not to bend float arm while removing.

INSTALLATION

CAUTION: Whenever the fuel pump module is serviced, the rubber seal (gasket) must be replaced.

1. Using a new seal (gasket), position fuel pump module into opening in fuel tank.

2. Position lockring (5) over top of fuel pump module.

3. Rotate module until embossed alignment arrow points to center alignment mark. This step must be performed to prevent float from contacting side of fuel tank. Also be sure fuel fitting on top of pump module is pointed to drivers side of vehicle.

4. Install Special Tool 9340 (3) to lockring.

5. Install 1/2 inch drive breaker (1) into Special Tool 9340 (3).

6. Tighten lockring (clockwise) until all seven notches have engaged.

7. Install fuel tank (Refer to 14 - FUEL SYSTEM/ FUEL DELIVERY/FUEL TANK - INSTALLATION).

 

[MFalkinham]

Here's my question (finally). I don't remember seeing any type of O-ring or gasket. Is it possible I missed it and it fell into the tank somehow? There's nothing on the ground. If so, what color is it (black or maybe clear?) I'm trying to recall any items down in the tank that I might have overlooked. It seems that a gasket would have raised the pump enough to "snug it up" and helped to make the retaining ring go on more tightly.

Ok. The next step is to burn up my $100 new tank of fuel so that I can lower it again and recheck the pump/ring fitting.

If memory serves, the rubber gasket was black and was shaped with a ridge so that part of it was on top of the opening, and part was around the inside. It very well could have fallen inside while you were replacing the pump, as mine did, but I saw it fall and then fished it back out.

Why not buy a siphon and temporarily drain the fuel into 5 gallon pails? That way you can fix this ASAP.

 

[Walker]

Allright. I guess that pretty much "seals it" haha. It's definitely the gasket (pump sealing proceedure of this process) that I've got screwed up. I sure don't remember seeing anything fall off or into the tank. I even spent a few minutes raking out a few crumbs of junk that had gotten into the tank. I'm hoping maybe it stayed on the pump, but it sure didn't seal up right if it did.



Oh well. Atleast I have a nice lift to borrow to do the whole process over again. I think I'll head over to the Dodge house and buy me a new gasket for the next operation so I'll know for sure that it actually does exist. I think the old one must have been swallowed up in that black hole where those missing dryer socks go to die :-laf

 

[Turbo1Ton]

If memory serves, the rubber gasket was black and was shaped with a ridge so that part of it was on top of the opening, and part was around the inside. It very well could have fallen inside while you were replacing the pump, as mine did, but I saw it fall and then fished it back out.



Why not buy a siphon and temporarily drain the fuel into 5 gallon pails? That way you can fix this ASAP.

You're memory is pretty good. I had mine apart about 2 months ago to do this and the rubber gasket did in fact have a ridge around it. Mine stayed nicely in the opening until I pulled it out to wipe it off. I was very careful to make sure it didn't get snagged and pulled around while I was pushing the sending unit back into the tank.



Walker, I would be surprised if this wasn't your problem. As soon as I read this I thought of that.



Good luck.



Jeff

 

[CLAYTON]

I had the same type of leak around that seal. I thought that maybe the seal dropped into the tank but turns out that it was snug on the top of the tank. All I did to stop the leak was to heat up the cap with a heat gun and then quickly put it back on. Not only did it go on A LOT easier but it sealed the tank and I have had no leaks since. Maybe worth a try to heat that ring up.

 

[Turbo1Ton]

Good point about throwing some heat to the ring Clayton. I forgot that I had to heat the ring up with a heat gun just to get it started (David mentions this in the instructions also). Maybe it didn't get threaded on correctly.



Jeff

 

[evldsl]

Ok guys. Here's the story. After I talked to you David, I continued checking lines etc. and the only thing I can come up with is that it has to be at the retaining ring/ pump module seating. You can't screw up the fuel lines; they either "snap" on and hold or they don't (they were both tight). The electrical connector slides in and locks with the red sliding tab (as stated by the instructions), but this has no way to cause a leak. All hoses (old vent, new vent, and filler hose) are all dry (no cuts or holes).



When I took off the retaining ring, it was real snug and required a hammer and screwdriver to "tap" it loose to release. When I spun the ring off, the pump "jumped" up out of the tank about 3 inches because of the spring loads. When I reinstalled the pump (which only fits in one way) on the tank, I pressed it down (against the spring tension) and it never "sprang back up" like it did when I first unscrewed it. I then placed the retaining ring back on and spun it to the locked position. The ring had a little play after that and never really was "snug", and did not require me to hammer (tap) it back into a tight position. I thought to myself "hmmm, maybe the spring load of the pump has to force itself "up" against the retaining ring to help lock it tight and create a better seal (just a guess). So, I put it all back together and let it go thinking maybe the springs would eventually "pop" back up and seat.



Then for the fill-up. I hit 36 gallons and the fuel spill was on. About 2 gallons come spraying out from under the truck and the "oh . . it" face was on. Raced down the highway a bit to burn off some fuel to get the level down and then back to the garage. Took off the rear wheel. Lowered the tank to the end of the straps. Checked everything out. No leaks at the new vent fitting, hoses, fuel lines, etc. So, it has to be the at the retaining ring.



Here's my question (finally). I don't remember seeing any type of O-ring or gasket. Is it possible I missed it and it fell into the tank somehow? There's nothing on the ground. If so, what color is it (black or maybe clear?) I'm trying to recall any items down in the tank that I might have overlooked. It seems that a gasket would have raised the pump enough to "snug it up" and helped to make the retaining ring go on more tightly.



Ok. The next step is to burn up my $100 new tank of fuel so that I can lower it again and recheck the pump/ring fitting.



BTW. The install went great. No problems (with any of David's product). And I can't wait to get this puppy fixed right so I can "top it off" for real next time. I just might hit $120 this time

I installed mine on a 04. 5 so I can't be of any help but I do feel your pain with the $100. 00 in fuel cost.

 

[Bob4x4]

The 06 uses an o-ring and the retainer is also diferent from earlier models.



Bob

 

[Walker]

Project complete

Finally, 'Got-R-Done'. It was just as suspected, the O-ring was swimmin' (actually hung) on the pump down inside the tank. It had to of stayed attached to the pump when I removed it, then got off-centered and fell to the bottom of the pump. Can't believe I missed it. Oh well. Live and learn.



I couldn't stand driving around without it sealed up good for fear of debris, water, etc. getting in the tank. So, with just under half a tank left I attempted the fix. Bad idea ! I figured for around 12-15 gallons left and with two people it wouldn't be to heavy. Well several knife wounds from the tank shield later, I'm wishin I'd have waited til it was near empty again like the first time. I had it up on a lift, but ended up on the ground with two floor jacks getting everything into place. Took longer the second time after saying to myself "I'm gonna knock this one out real quick this time" (my second mistake).



Well, after re-seating the O-ring and hooking everything back up and checking for leaks, all was good. So, I headed to the station to finally "top it off" for good. Being cautious after the first disaster (the little Exxon Valdez incident), I ran the pump nice and slow with my eyes under the rear wheel checking the top of the tank. NO LEAKS! With just under half a tank before fill up, it held another 24. 5 gallons. It filled up nice and easy all the way to the filler neck with just a couple of 'clicks'. Mission completed.



I had bought a new O-ring from the dealer "just in case", and got a printed page of the exploded view of the pump assembly from the parts counter. This page was not the same as what I had, and sounds like it is from the 05 and older models. It showed a wide, banded type O-ring with what some described as seating above and below the tank wall. This was not the case with mine.



Ps. For all you 06 owners. The fuel pump O-ring is GREEN. And is a solid round (tubular) piece that sits on top of the tank (in a recessed slot), and under the pump before setting it in the tank. The retaining ring then sits on the pump and spins into place (with hammer help), and seats into the upside down V-notched grooves on the retainer ring.



The pump is now as tight as a frogs @$$ and all is well. I give Dave's kit a big thumbs-up!



Pss. One final question. My OH comp. DTE reading is maxed out at around 450ish (give or take). I guess it can only read a certain max based on the stock float level readings (if this is how it works). I've driven about 50 miles since fill-up and the DTE has not moved yet. Anybody else seeing this with the mod?



Thanks Dave for the customer support.

 

[Turbo1Ton]

I think the DTE is averaged from the fuel economy or something like that. I have seen mine as low as 590ish all the way up to 660ish. Mine won't usually start dropping until I have about 120 or more miles on the tank.



Jeff

 

[Spooled-up]

Jeff,



Glad to hear it's all back to normal.



You didn't happen to get any pics of the O-ring did you?



I'd like to add them to the instructions. If not, no big deal. I'll get someone to do it.

 

[Walker]

Sorry Dave. No pics. Between the mud, the blood and the beer I forgot to think about it.

 

[Spooled-up]

No problem Jeff.