When the tank is filled all the way up gas can be smelled inside the car and sometimes there is also a leak.

What are the common failures in the gas tank area on the late 960's? I plan on taking the car to the gas station and filling her up and seeing where the leak is. I just wanted to check in with you guys first and see if there was something common that breaks, or if you had any other suggestions about how to diagnose it.

Thanks!

edit- response below

EDIT- Response below

EDIT- Response below

I installed the new hose on there today. All it took was a t25 torx bit and a 1/4" socket. I got the hose from the dealer for 50$.

I got lucky and the small hose popped right off the nipple and I didnt even have to undo the t25 hose clamp.

The hose clamps for the large outlets of the hose were easily removed with my 7mm (1/4") socket and 1/4 inch drive ratchet. Putting the torx hose clamp back on the hose was difficult. My big hands barely fit in there and I had problems getting the bit to go into the torx screw on the hose clamp. I eventually got it tightened down after about 30 min of messing around.

All this was done thru the inspection hole and with just the 1/4 inch socket, t25 torx bit, and a small 1/4 drive ratchet. Now I have some busted knuckles and a slighty sore back from being in the trunk for about 1.5 hours.

The rubber hose from the filler to the tank has a "Y" in it, it sometimes cracks at the "Y" and leaks fuel. You can access the rubber hose by taking out the carpet in the truck and removing the 4 bolts that hold the Fuel Pump/Level Sending unit access hatch on the rear uppser level of the trunk.

DEWFPO
--
1998 S90 071,245 and 1995 964 154,100

It turned out to be that exact hose, that Y shaped filler hose. It looked like it failed where the smaller hose connects to the gas tank. I have heard that these hoses commonly fail.


Was there a recall on this??? There is gas spraying all over the rear of the gas tank and even getting close to the exhaust(Dangerous). And the hose looks extremely difficult to replace.

I don't personally know of any recall. That same hose failed on our 95 960. I didn't replace the hose, I just hot glued the small crack that I found in the crotch of the "Y". So far it's lasted 6 months.

DEWFPO
--
1998 S90 071,245 and 1995 964 154,100

That's the same failure I had on my 93 960. The small hose was torn at the clamp close to the fuel tank. The clamp uses a small (10mm ?) torx screw. The head was facing the body of the car and was not accessible. Out of desperation I tugged on the hose and it came right off. Without lowering the fuel tank, I wasn't able to reinstall the clamp as it came from the factory. I put the clamp on the end of the hose and tightened it enough to keep it stationary on the hose. While attempting to tighten the clamp, while lying under the car using many extentions on my ratchet, the clamp came off of the hose and is now between the hose and the fuel tank. I attempted to remove the hose again so that I could get the clamp back on. The hose was happy where it was. I left it that way. I filled up with the hose installed and there was no fuel pouring out and no odor inside the car.

The hose was about $45.00 + tax from the dealer. The part number on the new hose was the same as the original.

On my 93 960 there is a valve of some kind on the right side under the lip of the access hatch. It's bracket is attached with two torx screws. I removed it to ease access to the small hose connection.

Hope this helps,
Michael Diamante
1993 964 95K

That hose sounds like a realy pain to change. Considering I could barely see the top of the gas tank through the IRS, there is no way I will be able to get tools up there.


I just have my fingers crossed that I may be able to get the dealer to fix it under a recall. This failure seems common and dangerous enought to be grounds for a recall. I just dont know if it is a recall.


I noticed the leak thru the inspection/access cover that I removed. I doubt there is any way to remove the hose thru that thing.


Please let me know any suggestions you may have regarding the installation of the hose, or if you know if its a recall.

Small hands help!!

When I changed the hose I first thought that I could do the job entirely from the top. I soon discovered that I needed to be under the car to see the small hose connection. I put a jackstand under the right rear jack point and was able to see the access hatch and hose connection. I used a torx bit on a ratchet with extensions to remove the screws to the valve that hangs down in the way on the right side. I disconnected the small hoses surrounding the fuel filler hose.
I disconnected the hoses from the valve and set it aside.
I disconnected the fuel filler hose from the fuel sending unit.
Using a combination of offset screwdriver and flexible driver, I disconnected the fuel filler hose from the fuel filler tube.

I then discovered that I couldn't unscrew the clamp to the small hose and thought that I might be able to cut it off. As a last attempt before cutting, I tugged on the small hose and it easily came off. If I had to do it again, I would tug on the small hose before disconnecting anything else.

Installing the new hose wasn't the easiest thing in the world. The large section
of hose fits tightly. Fit the hose over the fuel sending connection. Leave it loose so that you can twist it into position to slip over the fuel filler tube.
I had to wiggle and push and finally got the hose to fully cover the fuel filler tube.

When replacing the valve, attach the hoses before tightening the screws. There isn't clearance to attach the hose at the front of the access hatch if you tighten the valve bracket first.

I would consider using a different type of clamp for the small hose. Something easier to tighten and loosen. When I was attempting to attach the small hose and clamp the first time, I discovered that the body dips down and gets in the way of the clamp. A thinner clamp would be good.


Hope this helps,
Michael Diamante
93 964 95K

Dear Michael,

Good p.m. and may this find you well. Might I suggest you forward your replacement procedure to Steve Ringlee, Master of the FAQs, for inclusion in the next edition?

The detail you provide is awesome, and will save many bruised knuckles and strained muscles.

With every warm, best wish for a Good, Healthy New Year, I remain,

Yours faithfully,

spook

I installed the new hose on there today. All it took was a t25 torx bit and a 1/4" socket. I got the hose from the dealer for 50$.

I got lucky and the small hose popped right off the nipple and I didnt even have to undo the t25 hose clamp.

The hose clamps for the large outlets of the hose were easily removed with my 7mm (1/4") socket and 1/4 inch drive ratchet. Putting the torx hose clamp back on the hose was difficult. My big hands barely fit in there and I had problems getting the bit to go into the torx screw on the hose clamp. I eventually got it tightened down after about 30 min of messing around.

All this was done thru the inspection hole and with just the 1/4 inch socket, t25 torx bit, and a small 1/4 drive ratchet. Now I have some busted knuckles and a slighty sore back from being in the trunk for about 1.5 hours.