I just replaced the rusted and leaking fuel filler tube. Repair apparently successfull but... i had to yank a little hard to get the tube out of the rubber hose connecting to the tank. Result : either the hose cracked or is partially dislodged from the tank = anything over 3/4 or a tank produces a leak at the tank end of the hose.

Do I have to remove or lower the rear cross member (major work apparently) or do I have access to this hose from the trap at the rear of the back passenger seat?

I'm crossing my finger and hope for the best.

Thanks in advance for all inputs.

Edited June 4, 200916 yr by frag

It's quite possible the tank itself is rusted there. I don't think you can see that part of the tank through the access, all I can see on mine is the fuel pump connections.

It's quite possible the tank itself is rusted there. I don't think you can see that part of the tank through the access, all I can see on mine is the fuel pump connections.

 

Bad news as I feared.

Thanks Welder.

Maybe cutting a new trap over the fill rubber hose would do the trick and be less of a hassle than removing the rear cross member?

96 Legacy, so it's pretty rusted under there.

Of course if it's the tank that's leaking i wont be able to bypass removing the crossmember. But I doubt it's the tank itsel leaking cause the leak began just after I yanked at the hose.

Opinions?

The hose was stuck to the tube that connects to the tank directly, right? Most cars have a little pocket around that tube from the manufacturing process that is nearly impossible to clean, so it collects all the road crud and salt, rotting the tank. I have fixed rotted tank seams (and one bullet hole) before with a product called Seal-All, one larger rotted spot I used the Seal-All like resin with fiberglass cloth.

The earlier cars you could access the area you need from the rr wheel well, just remove the wheel and a sheet metal cover, the fill pipe right there, worth a look

Maybe cutting a new trap over the fill rubber hose would do the trick and be less of a hassle than removing the rear cross member?

96 Legacy, so it's pretty rusted under there.

Of course if it's the tank that's leaking i wont be able to bypass removing the crossmember. But I doubt it's the tank itsel leaking cause the leak began just after I yanked at the hose.

Opinions?

The earlier cars you could access the area you need from the rr wheel well, just remove the wheel and a sheet metal cover, the fill pipe right there, worth a look

 

I can access the fill pipe and even replaced it. It's the tank end of the rubber hose connecting the pipe to the tank I cannot access.

I checked the cover behind the rear passenger seat and, like Welder said, it only gives access to a cover on top of the fuel tank (leads to the fuel pump and fuel gage sender). but not to the hose.

 

If no one says otherwise, the only alternative to removing or at least lowering the rear cross member seems to be cutting a hole just to the rear of the fuel pump cover between the cover and the spare wheel well.

On the other hand, the rear cross member is pretty much rusted so maybe I could replace it with a good used one and strike two blows with one stone.

Anyone ever removed and replaced a rear cross member ? How much of a job is it?

Bump!

Anybody with experience removing and replacing rear cross member or slipping out the gas tank without completely removing the cross member on a 96 Legacy AWD or similar ?

The cross member is not that difficult to replace. The bolts are pretty easy to get at, just a lot of work due to the rear end and the struts being attached. You must do that in order to gain access to the tank. I removed the tank once and it took me several hours between dorpping the rear and unhooking all of the lines to the tank. Just look at oll of the connections carefully and go slow. You don't want to tear anything loose.

 

Good luck

My wife's '99 Forester had a similar problem. It's work beyond what I can do, so the local shop took care of replacing the filler tube.

 

I checked with them and they report for a fuel tank repair, they have to remove the cross member.

Thanks for all replies.

I will keep the fuel level at 2/3 max for the time being.

As soon as possible, i will go to the cottage and prepare for a multi days mechanical endevour spiced with bicycle trips to the nearby town (15 km) like I did two summers ago when I replaced clutch, timing belt and a left side burnt exhaust valve.

Shade tree mechanic work at it's best.

I'll report back.

Edited June 9, 200916 yr by frag

My wife's '99 Forester had a similar problem. It's work beyond what I can do, so the local shop took care of replacing the filler tube.

 

I checked with them and they report for a fuel tank repair, they have to remove the cross member.

 

Thanks for checking Thomcat.