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T4R 4th Gen. 2005 V6 4.0: Gas Fill Pump Constantly Stops; Dreaded Gas Cap Woes

Discussion in '4th Gen 4Runners (2003-2009)' started by cchantzis, Nov 4, 2024.

  1. Nov 4, 2024 at 4:06 PM
    #1
    cchantzis

    cchantzis [OP] New Member

    Joined:
    Nov 4, 2024
    Member:
    #43816
    Messages:
    1
    Gender:
    Male
    First Name:
    Costas
    I have a 4Runner 4th Generation 2005, V6, 4.0 and need your thoughts. Specifically:
    .
    1. Gas refilling is almost impossible; the gas attendant has to either set the pump to the slowest possible fill rate setting or restart the fill pump manually every 0.5 gallons or so. Obviously, there is a problem. I replaced the Charcoal canister and vent fuel filter between the charcoal canister and filler neck but so far, no fix. Unless I am mistaken, there is no check/vent valve at the top of the gas tank.
    So, what is the FIX please?
    .
    2. How To Replace Gas Tank Filler Neck to Non-Toyota Type with with Screw-type Cap

    Has anyone done a replacement of the dreaded non-screw type of Toyota gas tank filler neck with a non-Toyota part having a screw-type cap?
    .
    Why I want to replace it?
    The current Toyota cap design is the root cause of countless fault codes and related CEL problems. The cap design FAILS to seal properly. I have had Volvos for 20+ years and NEVER had an issue with the screw type or threaded cap design.
    Some people have posted that the fix is to get a cap from the Dealer or should I write STEALER !??? Yet, I have NEVER seen a photo in multiple angles for the correct design that seemingly SOLVES the dreaded and countless fault code problems. so, pleaseeeeeeee post photos, if you have, or at least post what is the correct Toyota part number.
    .
    I only need to replace the gas Filler Cap Shield - Toyota (77291-35130) for ~$42 2003-2009 Toyota 4Runner Filler Cap Shield 77291-35130. believe there are 2 tubes: the larger one for fuel refill and the smaller one for fuel vapors return. The trick is to match the OD of those 2 tubes with the respective tubing of my car.

    People might ask "Have you gotten a fault code due to the gas cap?"
    The answer is?
    .
    It is TRULY impossible to answer with certainty because apparently Toyota has designed their cars' electronic system to give combinations of numerous codes when in FACT ONLY proper functioning of the gas cap is the ONLY Root Cause!!! I have been studying in depth this problem in various Toyota forums for the last 4/5 years and NOBODY has a PERMANENT FIX Solution, NOBODY!!! I challenge the Toyota manufacturer to post here what is the true root cause and what is the proper solution? Replacement of the gas cap with one from the Toyota Dealership is NOT the proper solution IMO, period. The Toyota Cap Design is FAULTY/under-designed, thereby deficient.
    Why?
    Because Toyota's cap design depends on only 2 dimples around the cap to properly balance the cap's seal onto the inner lip of the metal filler neck and then seal around the top circular surface of the filler neck. A screw or threaded cap design with a seal provides a seal between the filler neck and the cap without any of the design deficiencies noted above. Simply stated: Can you balance yourself BETTER standing on only 2 Dimples of a circle or standing on a complete circle? ! Obviously, the answer is? Standing on a complete Circle or a filler neck design with screw/threaded cap type.
    And Yes, I have tried coating the seal gasket area with Vaseline/grease/lubricious fluids but when I do the "smoke leak test" it still leaks under the gas cap. It is a marginal cap/filler-neck design IMO. That is why I want to find out IF anybody has switched to the screw/thread type of design configuration.
    .
    Final question:
    Does Toyota sell any car in the US having a Filler Neck and Cap Design of the Screw/Threaded type?
    If so, which Toyota type, years, etc.
    .
    BTW, here is a very nice pdf file on How To Replace a Fuel Filler Neck Part. .
    Thank in advance for any thoughts, even if you have never done this type of replacement.
     

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