Jeep Wrangler JK - Evap Emissions Problem Fixed - Gas Tank Broken Nipple Repair - $20 Fix.
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- Опубліковано 5 вер 2024
- How to fix a broken Evap Line nipple on Jeep JK Gas tanks. This may apply to other Mopar vehicles of the mid 2010s error, Dodge, Jeep, Chrysler.
I was getting the P0455 and P0456 check engine lights, as well as the "GASCAP" light on my dash. This is a common problem with Jeep JKs, and a really easy fix.
When this nipple breaks off, you have two options, repair it, or buy a whole new gas tank. A new gas tank would be $600+ and if you brought this to a dealer, I could easily see this being a $800+ dollar fix.
You can fix this yourself!! For less than 20 bucks.
Other Videos that can help you
video detailing a similar repair but didnt go into much detail-
• 2007 Jeep Wrangler gas...
A video that gave me the idea and inspiration to make this, although this repair was on a dodge ram
• rollover valve repair ...
Another video showing gas tank removal and nipple repair
• Wrangler JK Fuel Pump ...
Links to products used to repair the gas tank:
Tension Pin/Roll Pin/Metal Sleeve-
www.lowes.com/...
JB Weld Steel Stick-
www.lowes.com/...
JB Weld Quik Weld-
www.lowes.com/...
Harbor Freight Drill Bit Set-
www.harborfrei...
P0456 Evap Code- I fixed my broken gas nipple without dropping the gas tank. After many months of trying to pass smog and multiple mechanics recommending that I needed to replace the gas tank which is not available and on national back order I found this video. I checked my gas tank connections and one of the nipples literally fell off as it did in this video on my 2010 jeep JK. I used the suggested microscopic copper tubing instead. 5/32 tubing fit without having to drill out the nipple. I cut the tube long enough to insert 1.5 inch on each side. I used rubber cement as one would for pvc pipping to seal the inserted ends. I then applied JB weld around the broken nipple to bond both ends. I let this all sit for 24 hrs and it worked. I drove 200 miles to clear the code off the computer. It then passed smog. This video saved me the cost of a new gas tank and labor.
Hey man, glad it worked for you and that I could help. 😁
Hey, do you have a link or product name for the "suggested microscopic copper tubing"? Thanks!
@@user-wr9nq2ii1o If I had to make a guess he's talking about the copper tubing in my video, in 5/32 diameter. That would be my guess. I would just stick with the roll pins though if you have a lowes near by
@@mike01166 The tube size on my 08 JK is actually between 3/16 and 5/32. Not sure if I can find the perfect pin size without having to do the drill work.
Thank you for the video! I just got quoted $2,200 for the replacement of the tank and I knew I could do that for cheaper. I found tanks for about $600 but then I saw this video. You saved me a lot of money! I appreciate the tips and detail. Going to get it done this weekend!
Glad I was able to help
This need to be a recall mine was leaking gas when filling up a 2018 jku with 48,000 miles!!!
One of the best videos that have saved me so much money. I was lucky and didn’t need to drop the gas tank. I had enough room to do the repair and it works like a charm, no check engine light or gas cap codes anymore! 🤙🏼
Glad to help!!
Cheers from TN. This was amazingly helpful. I just fixed my 11 JKU, largely using your methods. I was able to get it all done without dropping the tank, but only because your video detailed the process so well. I drilled my broken piece and attached piece to 3/16ths and then inserted a OD 3/16ths aluminum hollow rod (Amazon: k&s aluminum tube), then used JB Weld plastic to join the two, and lastly your brilliant jb weld steel stik to further tighten it.
My gas cap message went off immediately. Thanks so much! I can’t believe this website is free ha!
Hey buddy, glad the video was helpful for you. I made it with the intention of hopefully helping someone else out, so seeing your comment made my day! Congrats on the fix.
Hey you got any advice doing this without dropping the tank? I'm able to get under my daughter's jeep and get inside there pretty easy to handle it. Just wondering if you had any suggestions on it. Thanks!
@@jime7789 I do not. I was able to fix without dropping the tank. I’m pretty tall but was able to fit under there and fix it.
Thanks for the video. It was very helpful. I agreed to do this repair to a friends Jeep and learned a couple of things. First, the vehicle was nearly full of gas and I don't have the capacity to remove a whole tank of gas so I didn't remove the gas tank. This made it more awkward to work on but saved a lot of time and trouble. The result was not as neat looking as your repair but looks like it will still hold up. I temporarily wrapped some electrical tape around the fitting to prevent goobering it up with JB Weld. Second, I didn't need to drill to insert the 5/32 tension pin. It slipped easily into the existing fitting. Actually, I used a screwdriver to open the slot a little so the pin would stay in place as I reinstalled it with the epoxy. Third, I only removed the zip tie that was closest to the repaired fitting. This seemed to relieve the torque on the fitting but still left the hose with some support. The major downside of this method is that I would have preferred to rough up the plastic fitting a little more before using the epoxy. I cleaned it with brake cleaner. I think with the addition of the epoxy steel, it should hold up though. We'll see.
Still working?
Just discovered this, Mike. Thanks. I've already replaced my tank on my 09 JK once, about 25k. Paid a ridiculous amount. Got the code again at 65k last week. Smoke tested and bam. Same thing. I could pay to have this done, again. But I'm gonna try this. I dig the JK steel stick option. Gonna try it. May try and do it without dropping tank. But, we'll see. Great vid and thanks, again.
I did this, and my gas cap reading went away and my fuel mileage has gone up, although not much. Might need to replace emissions integrity module and vapor canister, too, but so far, I think this did the trick! Thanks so much for showing us this!
Bump. I just used this successfully to fix my 455 code. This video continues to produce results. Thanks!
Glad to help!
So helpful, literally waiting for Lowe's to open to go buy this stuff. Thank you!
Good luck!
I just broke that part trying to do the gas tank myself after replacing the fuel pump on my 10 JK. So here I go with that fix, thought I was screwed, hope I'm not.
Hey! Thanks so much for making this video! I had the exact same thing happen to me and I watched your video, went straight to Lowes, bought the items listed and in a couple hours (mostly drying time) I was good to go! I've driven around a bit and no check engine or gas cap light on as of yet, let's keep the fingers crossed! Thanks again buddy! Ira from Utah
Hey, glad to help!
Just did mine.
Took a total of about 20min thanks to your video.
I did mine without dropping the tank, I hope it works I'll find out soon
Update, it worked, no gas cap light!
Thanks again brother.
@@shottown911 glad it helped!
Great info helped with identifying problem. You do not have to drop tank and the better fit was a .17" SS tubing you can order online. Thank you
I jus found out that my jeep Wrangler has that problem, Im fixed it tomorrow morning, thank you for the good explanation
Just did this yesterday before I saw your video today. Basically the same repair except I used a 3/16 brass barbed fitting from Home Depot and drilled the plastic out to 15/64. I kept it to just the liquid epoxy and not the steel stik.
The aluminum tube from a bbq temperature probe can be cut and used with no drilling required. Perfect fit.
Do you have a link?
@@zackw7587 I don’t. I tried can’t send pics here but let me know if I can help
Ahh ha! Probe shaft you say! I’ve gotta a few of those lying around maybe I’ll try that first for fit👍 thx
Need a pic please
Thanks, man. You definitely went into solid detail. I stressed my butt off thinking I had to drop the tank. Was able to get up under without doing so & used an ink pen refill as a guide tube. A little heat & a nail and it was tighter than (inappropriate joke here). Thank you!
Glad it helped
Thank you!!! Great video. Did mine without dropping the tank. 2010 Liberty. First thing is remove spare tire. You will see a space between the rear support that your arm will fit through. I used a flexible right angle drill shaft made by Dewalt to drill out the top of the vent. Then the exact procedure tip did.
They make stuff from plastic that should be made from steel. (radiators, intake manifolds, etc.) Cool tag!
Small EVAP line fitting just broke off yesterday on my Nissan Titan. I am going to try your method. Thanks a lot Michael. Cheers!
I just superglued the plastic pipe back on and then surrounded it with 5000 psi JB quick, then put another layer on 30 min later. Very strong and good fix
Boy I got lucky with mine! Mine was the piece that plugs into the charcoal canister and the gas cap! Then unplugged the negative on the battery and wallah! It fixemy problems! Great video man!👌😎👍
You saved me a couple grand. New tanks are 1200 and hard to find. Used would still cost an arm and could still end up with this issue in the future.
glad that it helped you
I like your video. Saw another one where the guy pressed the roll pin together and closed the gap. Then he ground the pin until it slipped in without drilling the plastic. Glued it in and done. Keeping your fix in mind but will try making the roll pin fit without drilling the plastic out. Thanks for your video.
Thank you for the video! Mine is the same year JKU and exact same issue. I'm getting the material to recreate your results. Auto shop wants 1.5-2k for a whole new gas tank. Nope!
Good luck man, take your time, go slow, and you'll be just fine. A lot of people commented they could do it without dropping the tank. For demonstration purposes, and for fully understanding it, I chose to drop the tank. I did it mostly alone in a few hours.
Thanks again for the tip. Like the other comments, I was able to get to the inlet without dropping the tank. I used the JB Steel Stick and packed it on. Reset the ‘gas cap’ light and seems to be holding up.
Dude. You saved my life with this video. Thank you.
Glad it helped
Great video. Came across the same issue. Broken plastic tube on fuel tank side. Left tank in, after reading more feedback, I'm tryin the Windex straw from the bottle. Fit tight. Will try that then use epoxy. Hoping the engine light stayed cleared.
Glad it helped
Dude brilliant. Worked perfectly. Without dropping the tank. Thank you
Glad I was able to help!!
Thanks for the video, I just bought an 07 JK that I’m pretty sure is having this issue, I’ll be doing this next weekend!!
If you read some of the other comments, many people said they've been able to complete the repair without dropping the tank. Should save a bunch of time.
Have the same issue. Going to check mine out tomorrow. The gas cap didnt do the trick so hopefully this is it. I have a 2009 UK. Great video
I used the plastic straw from a Windex bottle for my inner sleeve and then cut the rigid plastic hose and added a section of rubber hose between to give it more flex.
Great Ideal , Thank you for your video. Had to drop my tank because the electric fuel pump assembly cracked around the o-ring seal.
Thanks my bro. I fixed mine today and used tube of antenna. Best Regards from Iraq
Glad to help! Cool that you found this video in Iraq. The internet is amazing
Hey great job giving info online helped me identify problem. But I did not have to drop tank I worked from rear of jeep. Fixable with SS tubing Size .17" SS tubing.
Michael, thanks for taking the time to make this video my breakage was the same as yours I was prepared to delete that line by blocking both ends until I saw your repair Idea I didn't have to do any drilling the 5/32 roll pin fit mine perfect. mix me some JB weld and let it set next day snapped the line back on reset the code problem solved. Thanks again Happy New Year
Glad it worked for ya
and one other thing I forgot to mention it can be done without removing the tank just have to be a little flexible
@@JerryFlowers-iq9lj yeah I didn't know that at the time and I don't think it would have made for as a good of video if I didn't remove it and show people how it's done. Glad you got it fixed without pulling the tank
Hey great video especially considering your first. I don’t have the problem but since I have a JK I watched it. Well worth the time- now I just need to remember it if the need arises down the road. Again- good job!!
Keystone Light, eh? I see you are a man of culture.
Haha I got it for free. Any free beer is a good beer in my book.
Thanks for your help brother!!! Thought I was gonna have to buy a new tank!! This video saved me $700!!
Hell yeah! Glad it helped you
I had to do the same thing on my 05 TJ but instead of using the putty I use the J-B Weld two-part epoxy because it's says gas resistant and it gets rock hard as well
Thank you so much!! Save me from taking my jeep to the shop and $$$.
Glad to help
Thanks for posting, excellent video. You've helped me solve this problem and save some money at the same time. Thanks so much
Glad it worked out for you!
I currently have the same issue and thought of the same idea although I’m not dropping my fuel tank. The broken nipped half in the vent line end is still in the vent line and I’m leaving it there. I’m gonna use some brass pipe that’s
2.5 mm OD out of an Amazon pack that has several sizes of these pipe pieces I can try. Since I’m not pulling the tank I’ll just have to find the right size 2.5 mm (I’m hoping) and insert it in the vent line end of the partial white plastic stem piece then add some superglue around edge of pipe then reach up on top of fuel tank and insert into the valve end then 🙏🙏🤞🤞. And maybe a little good luck prayer dance wish me luck!
This was great bro 👍🏾 thanks I needed that
Glad it helped
Amazing work. Thank you for the video,
I find drive cycles to be best completed on a half tank of gas. Because of the catalytic converter seems to be difficult to run on a full tank of gas.
@@CIAG4PNP huh? I'm confused
@mike01166 The Cat test on the drive cycle is the catalyst monitor test for smog inspection. In carb states, it is mandatory to pass on the cars onboard computer. If the gas tank is too full, the Cat test on the onboard computer will not run. I learned this after failing the smog test in California. The smog tec told me to run the drive cycle on 75% to 50% tank of gas. Because the computer will cancel that test if the gas tank is too full. So, on a full half tank of gas, I let the car warm up after sitting over night, reved the engine at 3k RPM for less than 2 minutes, and the OBD computer popped up a pass. Drove to the smog station and pass smog.
I put electrical tape around the nipple, it helped me pass my emissions but the check engine light came back on but the “gas cap” light doesn’t appear anymore. maybe it semi fixed it.
Great video thank you!
Thanks for a great video !
Great Job 👍 Bout to do the same thing in Texas on a 2010 Rubicon unlimited
Thanks
I have a 2010. The 5/32 size is floppy in the nipple. Didn’t even drill it yet Might have to go up a size
Great video amazing level of detail
Glad you liked it!
Good job man I have seen other vids and they seem to do a shitty job but yours looks better thanks for your vid bro
Mine jest broken thanks gave me good ideas.
Just broke mine. Ugh. Question. Can I drive with this thing broken? Understanding that it will throw a code of course.
Did your jeep also have a misfire? I have the check engine/gascap lights in mine, but also a random misfire.
I'm going to try do to this on a Caravan. I bought it used and only bad thing is the whole line/nipple is missing. Any thoughts on throwing some fuel gasket maker into the pieces for extra sealing ability?
Update, for my 2010 JK the exact same size tension pin you used, which I got is smaller than the line nipple?? and doesn't need drilling out so I'll have to widen it. 2. just curious, how did the line snap on? Because there is hardly ANY room with the green snap holder to go with that black weld.
How are you, boss, I found a rollpin that is exactly the same size as the hole in the line, so I don't need to make the hole wider with the drill bit. Do you think I need to get a bigger rollpin and make the hole in the line wider?
thank you!!!
Thanks good video! Do you empty out the tank before drop?
If you plan on dropping the tank, it would be ideal to have as little gas as possible. Gas weighs 6 lbs a gallon. Half a tank would add 60 lbs to the already 60 lb gas tank.
I had less than 2 gallons in the tank when I dropped it
Here is my dumb question for the day. I know how to get all the other lines loose, but have not figured out how to get the connector for that line off. I removed the tank because I thought I was going to replace it. I saw the broken nipple and started looking for a fix and found this. Don't see how to get the broken nipple loos from the fitting. I know I am missing something really simple.
Never mind, searched the right keyword and saw that you squeeze the clip.
man i have some case but never get engine light on i have couple of DTC ABS TC light on only
Did you smell any fuel outside of the Jeep? I have a strong odor on the passenger side.
I never smelled fuel. It would have to be a very big leak Id imagine to be smelling fuel. This line that cracked is just a tiny vent line for fuel vapors. I never smelled any
My 2013 has a sensor connected there and then the hose. They put all that weight on that crappy plastic nipple.
They should have sleeved that at the factory.
They definitely should have
do you really need to drill out the nipple? does the size of the hole matter?
I'm not sure the roll pins would fit without doing that. Sleeving the nipple with the roll pin gave it permenant strength and prevented it from breaking in the future. I guess if you could find a smaller diameter roll pin, you wouldn't need to drill it out. This is just what I did and worked for me
@@mike01166 appreciate the quick reply. I was worried that the hole needed to be a specific size for airflow. I bought a plastic hose barb set but theyre either too small or too big. :/ I'll just try to look for roll pins and jb weld along the break line.
@@BigElkification if you're near a lowes, guaranteed they'll have the roll pins. Think I even have the lowes part number in the video or description
@@mike01166 so I was able to find a metric roll pin. It fit snugly and didn’t require drilling. Problem is they don’t sell them at any Lowe’s, Home Depot, ace, or any auto parts stores.
you forgot to list the keystone beer in your items needed
Lol. I never drink keystone anyway but had a coupon for a free 12 pack
How long did you let the JB weld sit before you applied the steelstick? Thanks.
sorry, just saw this now. not long, maybe 30 mins
What exactly does that line go to? I know its an evap line but is it the vent line for the gas cap/filler neck?
Yes, it runs up to the filler neck
Same thing happened to my dodge. I dropped the tank & did the same exact repair and now I can't put gas in my truck. The pump shuts off every 50 cents. So aggravating.
Not sure why this repair would prevent you from putting gas in your truck. No gas passes through this line, just vapors. Maybe it's possible you clogged the line during the repair and it's some pressure thing preventing fueling but that shouldn't be. Is the fill line from the gas cap to the tank kinked somehow?
@@mike01166 no kinks. Today I used a compressor to push air through the vapor hose. I'm going to have to drop the tank again. I did the repair about 8 weeks ago and just came across your video seeing if anyone else had this problem. And last night someone pulled out in front of me and I almost t-boned them. I slammed on the breaks so hard my radiator cracked. Murphys law 🤣😂😂🤣😭😭
@@HotOneRecordz sorry to hear that. Not sure why gas wouldn't be going into the tank... Can you run something flexible down the filler tube and see if you can get it wet? Can't see why gas wouldn't be going down the filler tube just by doing this repair
Do they sell only that parts? or replacing whole tank is the only option??
I do not believe they sell parts. You need to repair it or replace the tank.
Did it end up coming back or is it still holding?
5000 miles on it, no check engine light. Works great, no issues!
now that this is a year later, and like most other commenters, I have this same issue. Did this fix it?
Yes. 100% fixed
So 1 yeah later did it work?
Yes problem never came back. 50k miles later still good
Modify the roll pin and not the plastic part
I was quoted $1,300 for parts and labor. Probably a dumb question, but is there any reason why that white cap can't be replaced instead of the entire tank?
I dont know why, i think the whole white assembly, with all its other line hook ups is all one piece and part of the tank. its not removable. Did you already pay to have yours fixed? Its pretty easy to DIY
@@mike01166 Not yet! But I'm glad I came across this post.
@@jordanalter a guy in the comments below said he repaired his without pulling the tank... its a tight fit and it was fairly easy for me to pull the tank to complete the repair. let me know if you have any questions.
@@mike01166 yeah the white assembly is melted in to the tank. Cant buy it.... you either do this mod... or buy a whole new $900 tank.
@@mike01166 how to hard is remove the tank, I have a wrangler 2013 two doors, you flush the gasoline from the tank?... one person can do the job?
Wats the name of the part
Of what part? The whole video lays everything out very specifically. Can you be more specific?
Can you still drive it when it is broken off?
Yoy can, but you will get a check engine light and possibly gas cap warning light. Also, it may have been just in my head, but I felt like I was getting worse gas mileage. I think it's a n environmental thing though, they are trying to prevent gas vapors from escaping into the atmosphere.
With the check engine light on the eco mode won't engage... I have had a evap leak for the last 30,000 miles and finally got around to looking at it and this is exactly what broke on mine..
I did something similar to my 2018 jeep jku with 47k miles but used G flex expoy because NOTHING will glue to that type of plastic.
But the nipple that fills the tank broke on mine along with this nipple as well! I like my jeep but its low quality made😢
But THIS NEEDS TO BE A RECAL FIAT CHRYSLER!!! Who in their right mid uses this crap plastic!! #jeep # fiat #CHRYSLER
West System 655-8 G
Has the issue come back?
Nope. Fixed for good. Probably have 30k+ miles on the repair, no issues
@@mike01166 nice I have the same issue going to look into that first before switch out the EVAP sensor on the canister
@@rauldelosreyes9909 if you end up doing the repair, a lot of other people in the comments said they were able to do it without dropping the tank. Dropping the tank wasn't too hard for me to do on my own if you run it down to empty first.
10-4 bud thank you
Or to really piss off newsome... you coulda just plugged the rigid tube and called it a day....?
Would have still had the check engine light
But fuck that guy
Everything on the Jeep Wrangler’s JK’s Rubicon Sierra all of them are cheaply made poor design they just don’t have it specially the supposed be such a rugged vehicle
It's just bad I have to do this due to a shop that broke it while they was replacing my fuel pump never told me and cut a straw and that's why the code p0455 pop up on my 05 dodge ram 1500. I'm either going to get my money back for the whole labor and there parts which was 690$ or they can give it to me in court with a lawyer of all the other half ass work they have done on my truck...highly pissed off to the point I want these MFs shut down
Great video but that scraping sound over all the audio....Shhheessh
Yeah dude I'm not a pro youtuber, I strapped a go pro to my head and filmed it to help people. Thanks for the constructive criticism though, means a lot 🖕
@@mike01166 Dude. You’re a hero. Bout to save me thousands of dollars. I’d buy you beer if I could. If you have a method to slam this badboy together without having to rip the tank down I’ll mail you a six pack.
@@blackbottomfilms1359 well you can buy me a beer anytime you want cashapp $mprairie or mike.prairie@gmail.com PayPal.
Lots of people in the comments said they have done the repair without dropping the tank. I only dropped it so I could examine everything and film it. If I did it again, I probably could do it without dropping the tank. If you're located anywhere near Los Angeles, come by and I'll do the damn thing for you
Blow your nose !
Huh?
Do you happen to know the part name for the tube that goes to your broken nipple you fixed? My hose was chewed thru