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Leak on gas fill hose


longwater

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I have been working on my Sunrader, getting it ready for a long trip that I hope will begin in late June. When I filled it with gas, I saw gas leaking from the fill neck, running down and dripping off the metal tube that goes into the fuel tank. The question I have is can I get to the hose by removing the screws that hold the cover that's around the fill cap? maybe 10 screws or so. After I filled it the leak stopped. I had it on auto fill while I cleaned the windows, I don't think I'm lucky enough that it would be just that simple that it was caused by the auto fill.

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I have been working on my Sunrader, getting it ready for a long trip that I hope will begin in late June. When I filled it with gas, I saw gas leaking from the fill neck, running down and dripping off the metal tube that goes into the fuel tank. The question I have is can I get to the hose by removing the screws that hold the cover that's around the fill cap? maybe 10 screws or so. After I filled it the leak stopped. I had it on auto fill while I cleaned the windows, I don't think I'm lucky enough that it would be just that simple that it was caused by the auto fill.

Longwater, I have 94 Dolphin that had the same leaking filler hose problem. The "non self serve" attendants in Oregon quickly pointed it out to me. Was on a 2000 + mile trip at the time. From underneath it looked like someone had drilled a 1/8" hole in the filler hose. I put a screw in it but still had gas on the concrete at every fill up. When I got home I pulled the 4 screws holding the outside fill cover to the side of the Dolphin and 2 screws holding the fill metal pipe to the outside cover. Then I was able to get a looksee at how that was attached. Ended up removing the pipe and hoses up to the tank. The main hose was badly deteriorated. Replaced both the main hose and the adjacent overfill/breather hoses. Mine had a assortment of hose clamps that I also replaced. Was a bit tight getting the old hoses off and the new ones back in. You have to go at it from both ends, looking through the outside hole while working with your hands under the rig. I remember the outside metal filling part went into a special reducer ribbed hose, then into a piece of pipe that looked like a 6" long piece of tail pipe, then into the regular looking (and leaking) piece of filler hose, then into the fuel tank. Was also a bit of a trick getting the ribbed section oriented in the right position to get the outer filler part fitted up. Its' a bit of a task but a good feeling when you're done. I bought the replacement hose AutoQuest, I would think most Auto Parts stores would have it or point you in the right direction. Also note the replacement hose should be specifically for gas fuel use. I took the old hose with me to the store to insure the right diameter. You should also not buy it to much longer than you need. It's sold by the inch and is quite expensive.

I've got to get the camera involved in these projects, I know a few pictures really clear up a lot wonder. Hope this helps, Chief

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thanks Chief, mine has a flexible hose that connects to the fuel tank then it attaches to a metal pipe that looks like a piece of exhaust pipe and it runs up to the area below the fuel fill, but as it turns up it goes through a fiberglass wall and has expandable foam shot all around it.

It sounds like I just have to jump right into this and expect the worst. I don't think that I can use both hands because of the fiberglass panel that the pipe runs through. I hoped that when I removed the cover around the gas cap I might be able to remove the hose and replace that, but are you saying that the metal pipe might have problems also?

I have about 3 weeks before we plan on leaving, I guess the fun starts tomorrow.

Anyone else with information or suggestions will be appreciated.

Thanks LW

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thanks Chief, mine has a flexible hose that connects to the fuel tank then it attaches to a metal pipe that looks like a piece of exhaust pipe and it runs up to the area below the fuel fill,but as it turns up it goes through a fiberglass wall and has expandable foam shot all around it.

It sounds like I just have to jump right into this and expect the worst. I don't think that I can use both hands because of the fiberglass panel that the pipe runs through. I hoped that when I removed the cover around the gas cap I might be able to remove the hose and replace that, but are you saying that the metal pipe might have problems also?

I have about 3 weeks before we plan on leaving, I guess the fun starts tomorrow.

Anyone else with information or suggestions will be appreciated.

Thanks LW

Longwater, my rig did not have the foam around the filler. I pulled all the piping and hoses to the tank because I did not know where the problem was. I think it had been apart before because there was extra hose clamps and zip ties on it. I doubt the metal pipe is a problem. I think mine was a shoddy chunk of hose from that piece of pipe to the tank, the other stuff looked ok. Good luck on your trip. Mine starts in a week. Chief

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  • 1 month later...

Longwater, my 78 chinook had the same issue. You might as well just rip off the hose and put a brand new one on. It's actually quite simple procedure. Rubber just deteriorates after awhile. :\ So it goes.

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  • 2 years later...

post-6887-0-10646100-1362534022_thumb.jp

I had a leak on the filler hose on my Sea Breeze. I got a 4" long scrap of 2" diameter steel pipe from the local muffler shop and hacksawed the hose and inserted and clamped the pipe into place. ¡problema resuelto!

Edited by douglitas
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My rig had muffler steel 90 deg elbows and gas approved rubber hose.

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  • 2 weeks later...

car quest and napa sell that hose sold by the inch had gas smell in both my 1978 and 1987 replaced all no more smell.

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on my rig the hose is about 8 feet long from the inlet to the tank, and the connection to the filler pipe is high up and inaccessible. I don't know how long my fix is going to last, but I am not looking forward to replacing the entire hose. I'll bet the hose is $10 a foot at least!

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Thanks for all this discussion. Last summer my 87 Dolphin started leaving a wet mark the size of a dinner plate every time I filled it. A look underneath revealed gas wetting the sides of the filler hose less than a foot from the fill hole, then running along the hose 3-4 inches before dripping off. I guess that the leak is in either the top of the large filler hose or else coming from the smaller overflow/vent hose that is right above it. Repairing it is #3 on my list for as soon as the snow is gone, right after roof leak repair and replacing the drains/shutoffs for the black water and grey water tanks. Aren't 26 year old vehicles fun?

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last spring i changed both hoses on my 87 dolphin. they were in very bad condition and i had a very strong odor of gasoline inside the rv. started at the filler neck then lowered the tank only a little to get them on. assemble metal neck to new hose insert in body hole down on to tank. raise tank till hose at the right point on outside. check length from old hose first. most of the org tanks have drain plugs . do this job ONLY OUTSIDE. a lot of fumes. i had a half a tank of gas .

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The ocean will thank you. May I ask what dollars the shop quoted since I need this also?

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I UNDERSTAND THAT I LIVE IN A MOBILE COURT I CANT WORK ON MYN AT MY HOUSE , I CANT KEEP IT AT THE HOUSE MORE THEN TWO OR THREE DAYS. THANKFULY I HAVE FRENDS OUT IN THE COUNTRY. BUT GLAD YOU ARE GETTING IT DONE.

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I have the 91 Odyssey by Coachman... I had the same problem and replaced the fill hose and the vent hose. they were only 22" long but NAPA sold me 24". (2" fill and 3/4" vent) easy as pie to replace. I just jacked it up to spread the tires away from the wheel well and it was right there. I used 2 clamps on the gas tank side and one on the fill side for each hose. Also replaced the gas cap to pass smog in California.

Anthony in South Lake Tahoe butwiggle%5B1%5D.gif

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I have the 91 Odyssey by Coachman... I had the same problem and replaced the fill hose and the vent hose. they were only 22" long but NAPA sold me 24". (2" fill and 3/4" vent) easy as pie to replace. I just jacked it up to spread the tires away from the wheel well and it was right there. I used 2 clamps on the gas tank side and one on the fill side for each hose. Also replaced the gas cap to pass smog in California.

Anthony in South Lake Tahoe

It's an Odyssey or a Coachman. Can't be both. Two different companies

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It's an Odyssey or a Coachman. Can't be both. Two different companies

Ohhh gosshhhh. Sorry for the mess up... crap do i feel sheepish.. bahhh.. I was just talking about that in the last blog.

I actually have a Conquest by Gulf Stream.

crapola, sorry

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  • 3 months later...

My 81 Dolphin was leaking from the main fill hose where the frame rubbed a hole in it. I tried to drop the tank to replace the hose with new but all the retaining bolt heads were inaccessible inside the frame crossmember. The clamp at the tank is so close to the frame it couldn't be loosened, let alone a new hose fitted or tightened. I ended up inserting a length of vinyl hose insid the filler hose all the way to the tank. No more leak when filling. The rub hole is well above the tank air expansion space so i doubt it will ever see raw fuel.

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  • 4 weeks later...

I have been working on my Sunrader, getting it ready for a long trip that I hope will begin in late June. When I filled it with gas, I saw gas leaking from the fill neck, running down and dripping off the metal tube that goes into the fuel tank. The question I have is can I get to the hose by removing the screws that hold the cover that's around the fill cap? maybe 10 screws or so. After I filled it the leak stopped. I had it on auto fill while I cleaned the windows, I don't think I'm lucky enough that it would be just that simple that it was caused by the auto fill.

I had the same problem. I just went to Napa and got a 24" fuel hose and a 3/4" vent hose. I put 2 galvanized clamps on each side (total 8) of the hoses. I took my fill hole off the body to make it all easier to install. Was an easy job, if you jack the rig up on that side it may make it easier to install to the tank.

Keep in mind, I have the V6 with a Conquest body so my gas tank and fill hole may be placed differently from the body. One of my earlier posts talks about the problem I had with other members' comments that helped a lot.

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  • 1 month later...

Filler gas tank hose was leaking, replaced both the upper fill 2" hose and vent 7/16 hose. Removed one rear tire and had plenty of room.

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  • 2 months later...
  • 9 years later...
On 7/21/2010 at 2:44 PM, george101 said:

Longwater, my 78 chinook had the same issue. You might as well just rip off the hose and put a brand new one on. It's actually quite simple procedure. Rubber just deteriorates after awhile. 😕 So it goes.

My 78 Chinook Newport is having the same problem. Do you remember where you got the parts and what you needed George? Thanks!

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You're responding to a post 13 years old. Unlikely the original poster will answer you unless it was me. Easiest way to find a new hose is to remove the old one and take it to an auto parts store. Have them match the size. It must be fuel line. Rubber hose is not safe to use

Linda S

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You actually have 2 hoses. The fuel fill hose (2” ID) and a (7/16” ID) vent hose.

These measurements are normal for your year truck. Definitely remove the old hoses first to double-check before buying new.

Fuel fill hose is specifically designed for this application. It’s very expensive to buy but the only thing to use. It’s sold by the running foot and only comes in straight lengths. It can be challenging to install. Making bends (even slight) can be difficult.

If you’re mechanically inclined and have sufficient tools you can try to do it on your own. A garage with a lift would be my recommendation.

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Fuel filler hose is $$$ as others have said. Like $1.00+ an INCH.

A hack that will help SOMETIMES is to use 2" exhaust tubing to make curves. The tubing comes in 30, 45, 60 and 90 degree prebent and of course straight . Just use a hose clamp at each joint.  

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  • 4 weeks later...

i have done two rvs my 78  and current  dolphin both had very deteriorated hoses. napa  has it . it is indeed sold by the inch for the large hose. i had to use a large jack to lower the tank part of the way down. gas fumes out of the outlet are  off the charts . do outside only a breeze is recommend . for got to add the friends shop  which is a farm shop had these monster wood ramps or you need a lift .

Edited by 5Toyota
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