Trunk gas smell? FAQ comes through for the umpteenth time

[Dick R]

I have been tolerating the typical trunk gas smell for some time.  I had replaced the fuel line, sealed the fume collection tank in the trunk, and replaced the O-ring, all without making much of a dent in the gas smell.  Then recently I noticed a few FAQ mentions of the fuel filler boot being prone to cracking and thereby a source of gas fumes.  I know it’s been mentioned numerous times before, but for some reason I didn’t check it. 

Unsurprisingly, when I removed the boot, there were cracks a-plenty on the non-visible bottom side. When I looked up the part, I noticed there were two different versions – I call them the long one and the short one.  While the long one costs around $35 - $40 online, the short one (mine) goes for $80-$95 online.  That prompted me to at least attempt do what has been suggested previously – seal up the old one.   I used some “Liquid Electrical Tape” that I happened to have.  It's applied with a small brush and remains very flexible after drying. 

I applied several thin coats to the cracked areas, both outside and inside the boot. 

The gasket looked pretty questionable as well, so I replaced it with a part from my favorite auto parts store – Home Depot.  They sell something called “rubber packing sheets” which are 6” x 6” sheets of flexible red rubber in 1/16” or 1/8” thicknesses.  $4 for the 1/16”, which is what I used.  Cuts easily with scissors and makes a fine looking gasket that ought to do the job for a long time.  By the way, I noticed that Lowes sells the identical product for only $2.  Go figure.     

The result – success.   Finally, no more trunk smell.  FAQ has the answer once again.   

[halboyles]

Also check the fuel sender tube bushing--see pics below.  This is commonly cracked or even missing entirely.  If you need one, PM me with your address and I'll send it out to you.

[Dick R]

Thanks.  I had replaced that part some time ago when the new fuel line went in.  The old one was pretty bad. 

[cree02]

Hey @halboyles do you still have any of those sender tube bushings around? 

[halboyles]

3 hours ago, cree02 said:

do you still have any of those sender tube bushings around? 

Indeed I do.  I just used one on my '74 3.0CS today.  Send me a PM with your mailing address and I'll get one out to you.

For those who haven't checked to see if it is missing, attached is an instruction sheet for replacing it.  I think that many times the sleeve is lost when someone is replacing the 8mm (5/16") fuel hose and doesn't realize that the sleeve has come off with the hose and is stuck inside of it.  Here is a pic of that exact scenario.

Fuel Sender Tube Sleeve Replacement.pdf