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How to Replace Fuel Tank Filler Neck 01-03 Ford Escape

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How to Replace Fuel Tank Filler Neck 01-03 Ford Escape

Created on: 2012-06-11

Check out this video to learn how to replace the fuel tank filler neck on your 01-03 Ford Escape. 1A Auto shows you how so you can do it yourself!

  1. step 1 :Removing the Fuel Filler Neck
    • Raise and secure the vehicle
    • Pull back the filler neck shield
    • Loosen the clamp on the larger fuel hose with a 6mm socket and ratchet
    • Loosen the clamp on the smaller fuel hose with pliers
    • Pry the fuel hoses off the filler neck with a flat blade screwdriver
    • Remove the 8mm bolt from the filler neck bracket
    • Open the fuel door
    • Twist off the gas cap
    • Remove the two 7mm bolts inside the fuel door
    • Pry off the fuel door housing with a flat blade screwdriver
    • Pull the filler neck down and out through the wheel well
  2. step 2 :Transferring the Filler Neck Shield
    • Punch the rivets out of the shield with a punch and hammer
    • Drill out the rivets
    • Take the shield off the old filler neck
    • Put the shield onto the new filler neck
    • Fasten the shield to the filler neck with coarse threaded bolts
  3. step 3 :Installing the Filler Neck
    • Lift the filler neck into place
    • Push the fuel door housing into place
    • Start the two 7mm bolts into the fuel door housing
    • Insert the 8mm bolt into the filler neck bracket
    • Tighten the two 7mm bolts inside the fuel door
    • Apply rust penetrant to the fuel hoses
    • Push the fuel hoses onto the filler neck
    • Tighten the larger fuel hose clamp with a 6mm socket and ratchet
    • Tighten the smaller fuel hose clamp with pliers

Tools needed for replacement

  • Drills, Drill Bits & Related

    Drill

  • Materials, Fluids, and Supplies

    Coarse Threaded Bolts (to replace rivets)

    Rust Penetrant

  • Pliers, Cutters & misc Wrenches

    Needle nose pliers

  • Ratchets & Related

    Ratchet

  • Screwdrivers & Related

    Flat Blade Screwdriver

  • Sockets - Metric

    6mm Socket

    8mm Socket

    7mm Socket

Installation Video
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Brought to you by 1AAuto.com, your source for quality replacement parts and the best service on the Internet.

Hi, I'm Mike from 1A Auto. I hope this how-to video helps you out, and next time you need parts for your vehicle, think of 1AAuto.com. Thanks.

In this video, we show you how to replace the fuel filler neck on this 2002 Ford Escape, same as any 2001 to 2007. Oftentimes, these filler necks rust out in both these Escapes and Mariners causing a check engine light to go on which usually says that you need to check the fuel cap or the vapor recovery system has an issue. The tools you'll need are jack and jack stand; 6, 7 and 8mm sockets with a ratchet; pliers; flat blade screwdriver and some oil or lubricant to help you put the thing back together.

You want to start out by jacking your vehicle up. This just gives you some clearance between the wheel and the wheel well. Then, right in behind that plastic shield you'll see a clamp. You can use a 6mm socket and ratchet or a screwdriver and then there's a pinch clamp that you use a pair of pliers on the smaller hose there. Here, I'm using a 6mm socket with a ratchet to loosen up that clamp on the larger hose. Once you get it loosened up, just slide it down the hose a little ways. Here, I'm using a pair of pliers, you want to pinch that clamp and then slide it up the tube. Once you get it loose, slide it a little ways up the hard part of the tube. I'll fast forward. Just work the screwdriver in there in about three or four different places and then just use some strength and twist the hose, get it to break the seal apart, and then pull it down and off. Then, do the same thing for the smaller hose.

There is an 8mm bolt right here, near the top of the tire that holds a bracket. Again, we'll fast forward a little as we remove that 8mm bolt. Open up your fuel door, take your gas cap off, and there are two 7mm bolts to remove. Again, I'm going to speed it up as I remove those two 7mm bolts. Pry up on this housing and pull it right off.

Here's the old one out, and actually judging by the look of this thing, it was probably just replaced not too long ago, because there's not a speck of rust on it. Usually, these things rust out pretty bad. I'm just going to reinstall my original one. If you were putting a new one on, you would want to take this and punch the center of these rivets out with a small sharp punch, drill the rivets out and take the shield off and then use some small nuts and bolts and put it onto the new one. You don't have to put the shield back on, but it does help protect it. It actually is designed to reduce noise, noise of rocks and things hitting the fuel filler neck, so you could put a new one out there without putting the shield on but I do recommend putting the shield on and that is how you would do it, you just punch these out, drill them out and then rebolt them to the new one. Like I said, this one's in great shape so I'm going to reinstall it.

Reinstallation is really just a reverse. Put it in, back in place. You just want to twist it so that you can see the threaded holes where the bolts go in. Put your collar back in place, get that lined up on the hole as well, and then I'm going to start one of my bolts in here. Then, start the other one in and just tighten them up a little bit, just to hold it all in place. I'll speed it up here as I, like I said, start those bolts in and then tighten them a little bit. Once you have the top started, then put the 8mm bolt back in the bottom bracket that's right next to the top of the tire. Then you can tighten that bolt up. Then once that bolt's tight, you can go back up to the top and tighten the two bolts that hold the filler neck at the top.

To reconnect these tubes, most likely your little pinch clamp probably fell off. Go in, put it on the smaller tube. If you want, put a little bit of oil or penetrating oil or something onto the tube itself. It helps to get the hose back on easier. Push the hose right on. For the lower one, bring it down, make sure your clamp is on the hose. I'll fast forward from here on out, it's a matter of sliding that clamp back up in place, using your 6mm socket and ratchet to tighten it up and then using your pliers to get the pinch clamp back in place for the smaller breather hose

We hope this video helps you out. Brought to you by www.1AAuto.com, your source for quality replacement parts and the best service on the Internet. Please feel free to call us toll-free, 888-844-3393. We're the company that's here for you on the Internet and in person.

Tools needed for replacement:

    Drills, Drill Bits & Related

  • Drill

  • Materials, Fluids, and Supplies

  • Coarse Threaded Bolts (to replace rivets)
  • Rust Penetrant

  • Pliers, Cutters & misc Wrenches

  • Needle nose pliers

  • Ratchets & Related

  • Ratchet

  • Screwdrivers & Related

  • Flat Blade Screwdriver

  • Sockets - Metric

  • 6mm Socket
  • 8mm Socket
  • 7mm Socket

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