99 OB Wagon Fuel Filler Neck Leak

[rd]

I recently got a CEL with the dreaded 440 error code. I started
looking around to see what may be wrong, and to my surprise, there was
a lot of rust around the fuel cap inlet. I removed the plastic cover
over the fuel filler hose in the wheel well and tons of dirt came out.
The whole pipe is rusted out to the point where a hole has formed in
the pipe! What a POS design to trap moisture and dirt right next to
the gas fill line made of steel !!
Has anyone else had this problem and if so, were you able to replace
just he pipe or were there other parts required?
I found the filler pipe online for $90, but I can't find the other
parts surrounding the pipe.
IMHO this should be a recall issue since raw gas can leak out the
holes and cause a fire, or at best, poor fuel economy and a CEL.
Bob

 

[John Varela]

I recently got a CEL with the dreaded 440 error code. I started
looking around to see what may be wrong, and to my surprise, there was
a lot of rust around the fuel cap inlet. I removed the plastic cover
over the fuel filler hose in the wheel well and tons of dirt came out.
The whole pipe is rusted out to the point where a hole has formed in
the pipe! What a POS design to trap moisture and dirt right next to
the gas fill line made of steel !!
Has anyone else had this problem and if so, were you able to replace
just he pipe or were there other parts required?
I found the filler pipe online for $90, but I can't find the other
parts surrounding the pipe.
IMHO this should be a recall issue since raw gas can leak out the
holes and cause a fire, or at best, poor fuel economy and a CEL.
Bob

That very problem came up on a recent broadcast of Car Talk, having to do
with a Toyota. In that case, Toyota no longer makes the parts. Click &
Clack suggested the caller either find the parts in a junkyard but warned
that if his filler is rusted out probably the junkyard ones are rusted, too.

 

[rsm96]

I recently got a CEL with the dreaded 440 error code. I started
looking around to see what may be wrong, and to my surprise, there was
a lot of rust around the fuel cap inlet. I removed the plastic cover
over the fuel filler hose in the wheel well and tons of dirt came out.
The whole pipe is rusted out to the point where a hole has formed in
the pipe! What a POS design to trap moisture and dirt right next to
the gas fill line made of steel !!
Has anyone else had this problem and if so, were you able to replace
just he pipe or were there other parts required?
I found the filler pipe online for $90, but I can't find the other
parts surrounding the pipe.
IMHO this should be a recall issue since raw gas can leak out the
holes and cause a fire, or at best, poor fuel economy and a CEL.
Bob

Hi Bob,

I just did this repair on my wifes 99 forester 3 weeks ago. I do not
know if Outback is same or not. I'd suggest at minimum getting all new
hardware, as every screw will likely all break off when you try to
remove it. There were 3 screws to hold the pipe to the body on top, 3
screws to hold tthe plastic cover to the new fillerneck and 2 or 3 th
attach a clip and the pipe to the car midstream. Her's also has some
sort of vacum valve at the top of the fillerneck on the Forester and 2
nuts to mount that. I also got that valve and new nuts, since that was
where her's was leaking. I needed to provide the car vin since they
changed design midyear. . Additionally I bought a new sheetmetal ring
and rubber seal that went in the gas cap side. The pipe was $90 and
the valve was $40 something. Add the other items and it totaled 150
something in parts including shipping. I bought parts from www.premiersubaru.com.
They were great, but this was a curse your subaru repair on the
Forester because the hose from the gas tank only came out less than 1
inch from the crossmember. The pipe is pushed in it about 2" into that
hose. When you unscrew everything there was not enough clearance to
slide the pipe out from the body to twist it and not enough hose to
grab to pull it out. I ended up prying the hose a bit loose with a
screwdriver and spraying soap between the hose and pipe to finally
free it after struggling a lot. If you have the same situation on the
Outback (too short a hose to grab) suggest you ask someone where you
buy parts or perhaps here or just remove the back seat to see if the
rubber fill hose can be disconnected from top of the gas tank via a
cover plate. If it can it becomes an easy job. Good news is that the
light has stayed off.. Yea - I agree with you that gas pipes shouldn't
have to fail. In fact in many years of car ownership I never seen one
fail. I think 3 lbs. of dirt/mud must have come out when i pulled off
the cover. I'd personally skip the junkyard on this as unless you
happen to hit on one that has been replaced, I doubt they could get it
in usable condition.

Good luck
Ron

 

[rd]

I recently got a CEL with the dreaded 440 error code. I started
looking around to see what may be wrong, and to my surprise, there was
a lot of rust around the fuel cap inlet. I removed the plastic cover
over the fuel filler hose in the wheel well and tons of dirt came out.
The whole pipe is rusted out to the point where a hole has formed in
the pipe! What a POS design to trap moisture and dirt right next to
the gas fill line made of steel !!
Has anyone else had this problem and if so, were you able to replace
just he pipe or were there other parts required?
I found the filler pipe online for $90, but I can't find the other
parts surrounding the pipe.
IMHO this should be a recall issue since raw gas can leak out the
holes and cause a fire, or at best, poor fuel economy and a CEL.
Bob

Thank you for the information on the Forrester and for the link. I did
end up ordering the parts from them as they were the cheapest stealer
I could find in Ct. I'll do the job once the parts are in and let you
know how it goes.
In speaking with one of the parts guys, he told me they have sold
literally hundreds of these filler tubes just in the Hartford CT area
this year! To me that sounds like it should be a recall or TSB. It's a
really poor design and the problem is obviously not limited to my
vehicle based on what the parts guys have told me and the fact that
ALL of the dealers I called STOCK this part. To me it's pretty
unusual to have a gas fill pipe go bad unless it's a chronic problem.
I have never had a problem with any of my vehicles gas fill pipes and
I usually keep my vehicles for 200,000+ miles.
I am going to enter a complaint with the NHTSA
http://www-odi.nhtsa.dot.gov/ivoq/ on the auto problems website. I
encourage anyone else with this problem to do the same. If they don't
know about it, they can't force the recall.
Regards,
Bob

 

[AS]

If you filed a complaint with the NHTSA you would make a big favor to
all Subaru users in the country and you might even get the parts for
free from Subaru in the way of a recall.

 

[rd]

I did file the complaint on the NHTSA website, but I can't wait for
them to take action. I need to fix my car NOW. I can't even fill with
gas since the air leak in the fill tube causes the gas nozzle to keep
shutting off at the pump. I'm also worried that if the gas comes up
too far in the fill tube, it will spill out the hole and leak down
onto my feet or the exhaust and start a fire.

PLEASE take the time to file a complaint if you have had this
problem. It only takes about 5-10 minutes. You will need your VIN
number to fill out the on-line form.

Thanks,
Bob

 

[AS]

I understand, but if the recall comes about, Subaru may reimburse you
for the parts. Keep all your receipts.

 

[rd]

On Sun, 16 Dec 2007 16:25:32 -0500, rd <n> wrote:

I installed the new fuel filler pipe and the CEL has not come back on
yet. Installation of the pipe was not too bad. Removing the old pipe
was difficult as the other reply stated. I ended up having to drill
out the screws at the gas cap end since they were rusted in so badly.
Once I got those out, I worked on the gas tank end where the fill tube
connects to a length of rubber hose. The old pipe was stuck into the
rubber connecting hose pretty well. I was able to get a flat
screwdriver between the fill tube and rubber hose and squirt some WD40
all around. After letting it sit for a while, working from the wheel
well, I used a long screwdriver to push the rubber hose back while
pulling on the fill tube. There was about 1/4 cup of gas still in the
fill tube which I caught with my oil drain pan (wide opening on top).
To install the new tube, I lubed up the hose end and got the end
started from under the car, then working from the wheel well, I was
able to push on the fill pipe to get it to go into the rubber hose.
After that the rest was easy

I hope this helps someone else with the same problem.

Regards,
Bob