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-
https://www.youtube.com/watch?v=ddG4HK2UiYA
A video that gave me the idea and inspiration to make this, although this repair was on a dodge ram
https://www.youtube.com/watch?v=NsHO5gzyYjI&
Another video showing gas tank removal and nipple repair
https://youtu.be/y8AOMGfviow
Links to products used to repair the gas tank:
Tension Pin/Roll Pin/Metal Sleeve-
https://www.lowes.com/pd/Hillman-5-32-in-x-1-1-4-in-Tension-Pins/3012969
JB Weld Steel Stick-
https://www.lowes.com/pd/J-B-WELD-Steelstick-Gray-Steel-Epoxy-Construction-Adhesive-Actual-Net-Contents-2-Fl-Oz/3389024
JB Weld Quik Weld-
https://www.lowes.com/pd/J-B-WELD-Kwik-Weld-Syringe/1002695264
Harbor Freight Drill Bit Set-
https://www.harborfreight.com/titanium-high-speed-steel-numbered-drill-bit-set-60-pc-63764.html
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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.
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
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.
Thank you so much!! Save me from taking my jeep to the shop and $$$.
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
Did your jeep also have a misfire? I have the check engine/gascap lights in mine, but also a random misfire.
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.
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
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.
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?
Just broke mine. Ugh. Question. Can I drive with this thing broken? Understanding that it will throw a code of course.
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.
Mine jest broken thanks gave me good ideas.
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!!
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.
So helpful, literally waiting for Lowe's to open to go buy this stuff. Thank you!
do you really need to drill out the nipple? does the size of the hole matter?
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?