Filler Neck 'Rubber part' available?

[Morency]

Ok, so on top of the leaky fuel tank, I realise I also have a leaky filler neck.

I could deal with the fact that I can fill my tank over 'Half-tank' but now the leaky filler neck piss me off.

It need to be fixed real bad. I do 11.5L / 100KM if we consider the leak, that's a major fail.

Mine is leaking at the rubber part. I cleaned up real good and put RTV on there, but it still leaks so I need a proper solution....

Anyone have a filler neck in great shape ? Or know where the replacement rubber part can be bought?

Toyota show in N/A for part number 77011-16040 (PIPE SUB-ASSY, FUEL TANK FILLER, LOWER (NOT AVAILABLE)

[dlb]

if the tank is bad as well, i would get the whole schbang from a wrecker. do the wreckers near you have any tercels?

keep in mind, the 4WD tercel tank is not the same as the 2WD tercel gas tank.

[Petros]

There are almost no sealants that will work against raw gasoline (there are several very specialized and costly two part rubber sealants used in the aircraft industry that would work, BMS 5-95 among others). It would be an easy thing I would think to make a gasket from rubber sheet stock you can buy from an auto parts store. Use the old one as a pattern and cut out a new one. Sealant on the screw holes might not be a bad idea as a secondary measure, but not as the primary sealant. If you have a crack in the filler neck that leaks the only solution is to replace it, or use the same sheet rubber with a clamp. When you buy the rubber gasket material make sure is is gasoline resistant.

[Morency]

Funny thing is, I work in a major aftermarket fuel system company. I design fuel modules / fuel pumps / fuel tank for Spectra Premium.

We produce one of the only aftermarket tank available for the Tercel 4WD called 'TO1A'.

Now, on our redesigned tank, the filler neck is welded to the tank, which is different from the OEM so I can't replace the component only.

For gasket wise, I could get a lot of fuel resistant plastic arround here but it's really the 'Flexible' part of the filler neck that is leaking, so gasket wouldn't help.

Now, I would prefer to simply fix the filler neck since If I drop the tank, I'm sure gauges, fuel lines, straps, will need replacement....

That's the kind of situation I could have avoided if I didn't bought a 1987 to be used as a daily driver...but I love old cars, and that 4WD tercel was so tempting...

Oh god, now I need to make it work.

[Petros]

unless you have a total rust bucket, the straps, fuel sender, pick-up etc should all be good and useable on the new tank. Just swap the whole thing over. If you want to repair the neck, cut out the section where the leak is located, get a fuel compatible length of rubber hose the same dia, and clamp it on with a hose clamps. Problem solved, no adhesives or sealants used.

If the leak is in the neck at the flange, you can try to use epoxy or something similar (that BMS 5-95 would work well), or perhaps some Marine grade polyeurethane sealant. prepare the surface well or it will too peel off.

[ARCHINSTL]

I guess your place of employment begs the question: "Why not get a tank from work and replace the whole thing?"
Surely you don't have to "pay retail," do you?
Tom M.

[dlb]

tom, i think morency said that he would prefer not to pull the old tank due to how rusted everything is.

[Morency]

I did some research tonight for a fuel tank in a scrapyard. There is only one, about 1h drive from my place, that is in descent condition according to the scrapyard. They ask 120$ for it, now way I'll pay that money for a car I've paid 500$, especially for a used tank that might also leak.

Even if I work for the company who produce the tank, they don't give me a good price at all. I got a quote of 192$ + taxes.On top of that, straps and surely gasket for gauges and pump will be needed. Again, no way I'll pay that kind of money for the 4WD. I love it, but I need it to be anything but another money pit. I already have 3 cars to invest money on.

I've found a filler neck on one of the samples we bought for development at work. It comes from a 1988 chevrolet nova, which is pretty much the same thing as a Corolla from the same era. It's almost the ame tank with different 'clocking' for the pump and gauge. Bolts holding the filler neck are rusted, and 8MM ratched couldn't get them loose, so I have no idea how I'll even be able to remove mine from there yet. Right now, there's a pretty thick coat of rubber from previous attempt to fix the leak.

Only cheap and logic solution I have in mind would be to pull the cup out of the filler neck, and find a rubber hose to fit in there so the fuel doesn't get in contact with the wall of the filler neck, and drop straight into the bottom of the tank.
I'll try to pull the cup (part holding the gas cap) without too breaking anything on the sample at work before any attempt on the car.

What a mess, I hate fuel leaks. It's my first time dealing with that issue, and I hate to see my money dropped on the ground every I time put gas in it. What a bad feeling...

Thanks for the support guys.

[splatterdog]

These tanks are incredibly cooperative, even when rusted. I've pulled 2 tanks from fatally rusted T4's without too much trouble. The last one(recently) was for a fix. The return line on the sender started leaking. So had to drop it. Ended up breaking what was left of the sender return pipe and plugging it's hole on sender and running a hose up to the filler. That didn't help keep the drivers control arm from rusting off though(pics to come). I've found that T4 bolts are better than many others. Just scrapped my old 84 and not too many bolts broke, even the little 10mm head body bolts.

The only way to make this cheap is to goop on a fuel tank epoxy. Your results may vary...

Time for an employee discount and be done with it. You can always move it to the next one. Not sure if they are directly part of your company, but thanks for the USA made radiator I installed not long ago(non T4). It had been a while...

If you pull it, just be careful. Mainly when trying to remove the hoses from the sender pipes. Penetrant applied several times before going in never hurts either. NO incandescent trouble lights either. When dropped/dripped on they make a great igniter.

How about a group buy everyone? I know I'll need one sooner or later. I don't want an outboard can in the back with me.

[Morency]

I do like the outboard can idea, but If I end up doing it I think I'll keep it for me

For a group buy, at this point maybe I could argue within the company to get a retailler price, I know it could be cheaper than the actual quote the gave me. Could be 120-140$, can't tell. See how many of you would take one, and I'll see what I can do.

We want that under our rust bucket!

[dlb]

ahhhhh, THAT'S why the gauge always says the first half of the tank goes so fast! i love being able to see it.

[Morency]

Temporary solution. Hopefully It won't take 2 hours to put 10L in the car, but diameter is kinda small for the flow gas station give...!

.75'' ID tube to 1/2 ID tube. Gas station gun fits tight in the .75'' (It's something like .828'' FYI)

I removed the filler neck from the tank we had at work. There is some kind of vent inside the filler neck, called FLVV ( that's what stop the gun at the gas station, so only a 1/2'' could fit in there.

I'll hunt for a cheap tank arround, I'd be ready to pay a max of 75$...Let's see what I'll end up with!

[Petros]

No need for a group purchase, RockAuto has Tercel 4wd fuel tanks for only $100 (includes filler gasket), the most costly brand they carry is only $135. that one includes the one piece filler neck (looks just like the one pictured above).

http://www.rockauto.com/catalog/moreinfo.php?pk=17815

BTW, soak the rusted fasteners in ATF over night, it is the best rust buster ever.

[Morency]

I take note for the ATF advice.

For the TO1A from rockauto, it's 154$ canadian, and it's the only one available for 4WD.

With shipping, it end up over249$ for the tank, plus duty cost on arrival.

So, don't expect to have a brand new 4WD tank for less than 250$, especially if you are in canada.

[dlb]

how close are you to the border? if you can get a friend in the states to buy it for you, you could pick it up from them.