Rusty Fuel Pocket

[WNYGT5-0]

Wow, that kinda sounds dirty. Anyone have any clever fixes for the ole s197 rusty fuel pocket? It looks as tho it’s been repaired previously, and while I have it apart I figure I might as well add that to the list. Don’t see much for oem replacement, not really accessible fully in the trunk unless you can shrink yourself. So unless I go to a bone yard with some cutting tools there’s not much you can buy over the counter to remedy the situation. I’m toying around with the idea of taking a 2010-2014 s197 fuel pocket which is available for about 40 bucks and removing the affected area from my car and trimming and implanting the late model s197 fuel pocket. Thoughts?

 

[WNYGT5-0]

Dead in here. I at least expected one naysayer to give me some crap. Oh well. Moving right along. Here is a 2014 Fuel pocket for some reference.

 

[01yellerCobra]

My guess is you're in new territory here. I can't say I've heard of this area being a rust issue. But then I don't normally have to deal with rust where I live.

 

[WNYGT5-0]

Instances first arose around 07-08, guys who store their cars and wash and wax religiously started seeing paint bubble inside the fuel door. The way ford set this up is very dumb and allowed for water pool and intrusion in the fuel pocket. The real damage is hidden behind the filler neck mount. Ford was made well aware of it but never did anything short of remedying the situation in the late model s197 body overhaul. In the early s197 the fuel pocket is Seam sealed to the outer fender then then glued to the inner fender and the quarter is spot welded into its final resting place. In the late model s197 the fuel pocket fits into the rear quarter from the outside of the car, no water intrusion.

 

[Juice]

Is that the "no gascap" style filler neck?

 

[WNYGT5-0]

Is that the "no gascap" style filler neck?

Yes, but as far as I can tell my filler neck should fit right in. I’m assuming here that ford also changed the filler neck due to the tanks internal check valves filling problems.

 

[RED09GT]

This is the first time I have ever seen this issue. I didn't open the thread as I had no idea what this is about.

 

[WNYGT5-0]

This is the first time I have ever seen this issue. I didn't open the thread as I had no idea what this is about.

That’s ok man, I searched around a bit and don’t find much chatter except from new owners who were extremely pissed. I’ve chatted a bit with the local Ford body guy, he’s the one who told me that ford was aware and had made revisions to alleviate the water intrusion.

 

[KonaMustangGT]

Looks like the later car has a tiny drain hole at the bottom of the door opening the earlier car doesn't.

 

[JeremyH]

Never heard of this issue either.

 

[WNYGT5-0]

Just walking around out back at ford, nothing to see up in there... Business as usual in there, right?


Well, No, not exactly...

 

[bujeezus]

Holy shit. Never heard of this before today.

 

[RED09GT]

Just looked at mine. Other than the coating of black rubber from the track, it is still mint.

 

[Sky Render]

A buddy of mine was a Master Ford Tech who owned an initial build '05 GT. When he helped me work on my '11 GT, I remember he kept talking about all of the fuck ups that were on his car that were "fixed" on mine.

Would it be possible to cut all the rusted stuff out and completely replace it with the capless system from the later S197?

 

[RavenGT]

Yet another reason to avoid the 05-08 cars.

 

[WNYGT5-0]

Would it be possible to cut all the rusted stuff out and completely replace it with the capless system from the later S197?

I believe that’s the way I’m headed, the question is now, to take away material or add it. Thanks for commenting.

 

[bujeezus]

A buddy of mine was a Master Ford Tech who owned an initial build '05 GT. When he helped me work on my '11 GT, I remember he kept talking about all of the fuck ups that were on his car that were "fixed" on mine.

Would it be possible to cut all the rusted stuff out and completely replace it with the capless system from the later S197?

That's why I've always steered clear of first year production models. They're still in their teething stage and use consumers as guinea pigs.