I have a '95 Disco I that just started leaking gas from the vent hose when filling at high volume (I can avoid the leak by filling it a low rate). The host is cracked right where it's hooked to the underbody body a few inches from the filling side.. In order to fully replace the hose requires removing the gas tank. I'm thinking about splicing in new hose for the last foot or so from the filling side. Has anyone tried this? Any recommendations?
Thanks.

 

Do it once and do it right which will last another 26 years. Get yourself some Gates Fuel Hose/Line in 3/4 diameter. Support the tank on the drivers side with a jack. Loosen and remove the 4 bolts which hold the OEM skid plate on. Loosen the hose clamps on the large main fuel inlet hose which goes up to the filler neck, and then loosen/disconnect the old rotten vent hose from the filler neck assembly. Open the rear cargo door, and remove the lower black plastic door trim which holds the carpet down. After that you should be able to get the carpet free. Once the carpet is out of the way lift up on the thick rubber/foam padding and remove the fuel pump access panel. Now gently lower the tank until it's being supported by the right frame rail. You want it low enough so that you can reach the spot where the 3/4 vent line attaches to the tank. When you go to install the Gates 3/4 Fuel Line it will be a little harder to slip on so I'd use some WD40 to get it to slide on. Then use a new hose clamp to secure it. Re-install is the opposite of the install. BINGO you're all done and it will last you longer than the weak OEM rubber hose as the Gates Fuel Injector 3/4 is a much stronger hose. DO NOT get the aftermarket AllMakes4x4, Britpart, or URO replacement to the OEM vent hose. The quality is truly **** poor and I've seen a new aftermarket vent line fail in as quickly as 2 weeks. The Gates hose will probably cost you around 15.00 for 3-4ft vs 20.00 for the aftermarket junk. On a D1 without any rust I've done this repair in as quick as 30min from start to finish.

 

helps to have little gas in the tank

 

Best4x4, your instructions are clear and your advice is sound. I really appreciate your help. Thanks!

 

Good point, disco96sd. Thanks.

 

Best4x4, I found Gates Safety Stripe II in 3/4" in NBR (Nitrile Rubber, a synthetic rubber) from O'Reilly:

https://www.oreillyauto.com/detail/c...ose/gatr/27010

Any issues with NBR?

Thanks.

 

That should work anything fuel rated = should be fine. It's also spiral reinforced vs the OEM and aftermarket which is just solid rubber. Shouldn't have to worry about that vent hose for a very long time after it's replaced!

 

Excellent. Thanks again Best4x4 for your quick and helpful replies.

 

No problem at all and glad to help!

 

Definitely head the advice about getting the tank really low before pulling it. That thing gets heavy laying underneath with 40L of gas in it!