Recall # 786

Visit Geno's Garage for Truck accessories.

• Saltillo ("G" in the 11th VIN position) and built through 2/26/98 13th hour (MDH 022613)
• St. Louis North ("J" in the 11th position) and built through 2/24/98 13th hour (MDH 022413)
• Lago Alberto ("M" in the 11th position) and built through 2/24/98 10th hour (MDH 022410)

Repair:
To correct this condition, the heat shield attaching bolt must be removed and the chassis fuel tube must be inspected and replaced if necessary.

Five unique fuel tube packages are required depending on the vehicle model and wheelbase.  Dealers will not be supplied with parts!  The expected small number of vehicles needing parts permits parts being ordered daily if necessary, for those needing fuel tube replacements. Dealers are requested to order parts only after inspection has determined that fuel tube replacement is required.

Inspecting the fuel tube:

• Remove white plastic heat shield covering chassis fuel tube (fig 1).
• NOTE: for V10, roll shield up and above exhaust pipe and then slide shield forward to remove.
• Disconnect 3 fuel tube supports.
• Remove front and center nuts for the heat shields (fig 2).
• Inspect fuel tube for damage from contact with center heat shield bolt (fig 2).

The repair involves replacing the fuel tube and replacing heat shield bolt.

1. Remove fuel cap.
2. Remove protective cap from pressure test port (located on top of fuel rail near TPS).
3. Using fuel pressure gauge tool set 5069,  release pressure in fuel rail.
4. Reinstall test port cap.
5. Disconnect fuel filler and vent hoses from fuel tank (fig 3).
6. Siphon fuel from fuel tank.
7. Use transmission jack to slightly lift tank.
8. For vehicles with 2 piece driveshaft, remove center bearing support and support shaft.
9. remove center frame stiffener if needed.
10. Remove fuel tank support strap nuts (fig 4).
11. Lower tank 3" maximum to gain access to fuel pump module connections.
12. Disconnect the fuel tub at both ends. (fig 5).
13. Remove and discard the fuel tube.
14. Reassemble tank, center frame stiffener, fuel filler and vent tubes
1. torque fuel tank strap nuts to 30 ft-lbs. DO NOT OVERTIGHTEN.
15. Pull metal heat shield down and apply RTV to shield at center bolt (fig 6).
16. Reinstall front attaching nut for shield. Leave center nut off. (rear nut should still be there)
17. Install the three tube clips.
18. Install white plastic shield (fig 1).
19. Remove driver (left) door sill trim.
20. Remove left kick panel.
21. Lift carpet to reach heat shield bolt (fig 7).
22. Remove and discard bolt.
23. Apply butyl patch over bolt hole.
24. reinstall carpet, kick panel, and door sill trim.
25. Refill fuel tank.

• Inspect fuel tube and remove bolt 0.4 hr
• Inspect fuel tube, replace fuel tube, and remove bolt 1.1 hr

This page was edited on: May 3, 2004