How to Repair a Fuel Neck on a 99 RAM 1500

The 1999 Dodge Ram was equipped with a metal fuel filler neck and vapor tube assembly. The metal filler neck extends to a rubber filler tube that attaches to the side of the fuel tank. The metal vapor tube runs parallel to the fuel filler neck, then routes to the top of the fuel pump. When the filler neck leaks, it is usually due to rust. Complete replacement of the neck is recommended, as repairs would only be a temporary fix. Accessing the top of the fuel tank is necessary to complete this job.

Instructions

1

Raise the hood on the Ram. Locate the fuel tester port on the fuel rail that has a cap similar to a tire valve cap. Remove the cap from the fuel tester port. Wrap a rag around the tip of a small screwdriver. Insert the wrapped end of the screwdriver into the tester port and depress the center pin slightly. Release the fuel system pressure for about two to five seconds. Allow any fuel that is expelled to soak into the rag. Place the cap back on the tester port and finger tighten the cap.

2

Raise the rear of the Ram, using a jack. Place jack stands beneath both ends of the rear axle housing. Lower the truck onto the stands.

3

Lay beneath the driver's side of the truck, just behind the split between the body and the cab. Place your jack below the fuel tank. Insert a plank of wood on top of the jack. Raise the plank of wood on the jack to the bottom of the fuel tank. Do not press upward on the bottom of the fuel tank with the jack and the wood plank. Remove the fuel tank strap bolts with a ratchet and socket. Pull the fuel strap downward and off to the forward and rearward facing sides of the tank.

4

Lower the tank halfway between the bottom of the truck and the ground. Remove the fuel vapor tube from the top of the fuel pump, using a ratchet and socket. Slide yourself in position to access the outer side of the fuel tank. Remove the rubber fuel filler tube with a ratchet and socket. Separate the rubber fuel filler tube from the metal filler neck. Use a flat-head screwdriver to slightly pry the the tube off of the metal if needed. Remove the rubber filler tube from the gas tank side by hand.

5

Move from beneath the truck and open the fuel filler door. Remove the three fuel filler neck mounting screws inside the filler compartment with a ratchet and socket. Pull the fuel filler neck and vapor tube upward and twist the assembly to completely remove the neck and vapor tube from the truck.

6

Install a new metal filler neck and vapor tube through the fuel door compartment. Install the three mounting bolts onto the fuel filler neck, and begin threading them by hand. Do not tighten the bolts completely so that you have maneuverability beneath the truck.

7

Lay beneath the driver's side of the truck and position yourself to access the fuel filler neck end. Install a new rubber tube and clamp onto the fuel filler neck. Tighten the clamp snug with a ratchet and socket. Install the rubber fuel tube onto the side of the tank by hand. Move the fuel vapor tube to the top of the fuel pump by hand. Slide yourself over to access the top of the fuel tank. Install the fuel vapor tube and tighten the clamp snug with a ratchet and socket.

8

Raise the fuel tank upward to the bottom of the truck, but do not press up on the bottom of the tank. Install the straps back around the fuel tank, and tighten the mounting bolts to 30 foot-pounds with a torque wrench and socket. Remove the jack and wooden plank from beneath the truck. Then position yourself at the fuel filler door area of the truck.

9

Tighten the fuel filler neck screws snug with a ratchet and socket. Raise the truck off of the jack stands, then remove the stands from beneath the truck. Lower the truck to the ground.