The Fuel Filler Hose Replacement Guide

A fuel filler hose is essential in connecting the fuel fill cap inlet to the gas tank, typically secured with hose clamps. When your fuel filler hose is cracked or worn out, choosing the right replacement is crucial. There are various types to consider, each with specific features and uses.

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Before replacing your fuel filler hose, it's important to determine certain factors:

Types of Fuel Filler Hoses

Straight or Curved?

First, check if your fuel filler hose is straight or curved. You'll likely need to inspect this by looking under your vehicle. Once identified, you can decide on the suitable type.

Straight Fuel Filler Hoses

Straight fuel filler hoses come in two categories: "Hardwall" and "Softwall". Each type has distinct characteristics that make them suitable for different applications.

Softwall Fuel Filler Hose

This hose has nylon cord reinforcement, allowing it to expand and contract over the barbed or flared ends of the filler neck and fuel tank connections. However, it can pinch or collapse under sharp curves like short 90 or 45-degree angles. Generally, the smaller the inner diameter, the more it can bend without collapsing. For example, a 1" inner diameter hose handles a 90-degree bend much better than a 2" hose.

Hardwall Fuel Filler Hose

Also known as Type A2 Marine, this hose has steel wire reinforcement, making it extremely rigid. It doesn't expand or contract over barbed or flared beads, requiring extra clamps for secure attachment. Despite its rigidity, it won't pinch off even when bent to extremes.

Ultra-Flex Sections

Our exclusive Flexible Fuel Filler Neck Hose Sections combine extreme flexibility in tight spaces with softwall end connections, allowing easy attachment to beaded and flared connection points. They can be connected end-to-end or attached to metal tubing for longer distances, ensuring long-lasting durability and strength.

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Angled Fuel Fill Hoses

If your fuel filler hose requires a curve, determine if it’s closer to a 45 or 90 degree angle. Angled fuel filler hose elbows provide flexibility and can be adjusted to fit specific angles. They can also be joined with clamps for multiple bends by cutting each elbow to the proper length and splicing together. A 90-degree elbow can open past 90 degrees to make roughly a 55-90 degree angle, while a 45-degree elbow can open up to roughly a 25-45 degree angle.

Hoses with Different Inner Size Diameter at Each End

Sometimes, fuel filler neck hose ends have different sizes. Manufacturers’ reasons for this vary, but it can complicate the replacement process. Using Inner Diameter (I.D.) reducers can address this issue by allowing you to fit smaller inner diameters without gaps or tightening problems. These reducers come in quarter-inch increments.

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Marine fuel systems are increasingly important due to the federal government's push to increase alcohol in fuels. E10 fuel, which contains 10-percent ethanol, has posed challenges for the marine industry. However, the industry has adapted by updating parts like gaskets, carburetor repair kits, fuel lines, pumps, filters, and injectors. Proper maintenance of your fuel system is essential to mitigate the adverse effects of alcohol-laced fuels.

Fuel Lines

An engine can't function without a steady supply of fuel. Older fuel hoses are prone to alcohol deterioration, leading to clogs, poor running, or engine failure. It's essential to inspect and, if needed, replace your fuel lines with new EPA-compliant hoses and clamps regularly.

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