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FUEL FILTER REPLACEMENT WARNING - Chevy Tahoe trucks Gmac 2000-2006 series...

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5.7K views 9 replies 4 participants last post by  bazar01  
#1 · (Edited)
I Nearly caught myself on fire. For DIY guys, consider you are on the ground on your back under a floor jacked (and hopefully supported) vehicle with limited clearance to work.

And I am just assuming these vehicles listed in the thread title are all similar. They may not be. But I think I just experienced the first significant design flaw in my vehicle/ - which is how these fuel filters are designed, positioned, and installed -and what it takes to change them. The fuel filter on my 2004 Chevy Tahoe is placed in-line between the tank and the engine and located just about under the driver seat. It has a compression fitting on the rear connection, and a push-in type tube connection on the front connection. A male union extending out from the filter front side and is attached by being pushed up into the fuel line coming off to the engine. That male extrusion is held in place inside the fuel line by expansion clips inside the line female side that you have to slide a ring shaped tool up in to get them to release so you can back the line off the male front side extension. The idea is to insert the ring tool, push the front line up onto that ring tool somewhat to expand the internal clips in the female connector, while at the same tile backing the whole contraption off the male protruding tube coming off the front side of the filter...

GMAC Created this where the line locks in too close to the fuel filter body and thus you have to use a "Low profile filter removal tool" to slide up in there. Which is a plastic ring sleeve of sorts which must be about 1cm in length maximum.

The long and short is you will wind up under there trying to wedge that PLASTIC ring tool up in there with a METAL screw driver like some kind of dumb monkey. Especially if you go to Autozone and buy their generic filter removal kit stated to work on these model vehicles, as it does not even come with any type leveraging handle to push the removal ring up in the front fuel line connection insert area.

WELL - My screw driver slipped and sparked and I guess I got lucky that the spark was not hot enough. Because my arm was soaked in gasoline and there was a pan of fuel laying next to me that I had just drained the remaining fuel from the line in after detaching the rear side filter compression type connection from the line.

It may even turn out that all I had to do was put the plastic removal ring in place around the line and and then push the forward fuel line backwards onto the filter and never have used a screwdriver. But the whole area is tight and releasing the body retaining bolt on the fuel filter strap appears to do little to free up the current installed filter for better handling. Its also easier said than done due to lack of space between the fuel filter and the front line female slip on connection. These "SLIP ON RING REMOVAL TOOLS" do not exactly just line up and slide in either. So you wind up with a screwdriver attempting for force the tool up into the female line end just to get it started.

I honestly DO NOT THINK that my low profile ring tool even went far enough up in the female front line connection to spread the internal prongs. Most likely they just finally gave way to the force of my wrench I used as a lever. And there is no way a longer ring tool would have fit in there. So I dont know I doubt there is an aftermarket tool out there that actually works right for this job....

The long and short is that by then and after my near arm kindling, I had the plastic ring tool somewhat worked up in there enough to eventually then get a wrench between the filter and the ring tool to use as a leverage pry arm and just brute forced it off. The internal clamp locks onto the original filter with a 4-prong metal clip that sits up in the female front line end. I guess I had at least two of them compressed back and the force of the wrench just stripped the other two forward. I DO NOT THINK the metal clip is intended as part of the fuel line and to stay in the fuel line female connector by intended design. I would speculate the female coupling is standard and the 4-prong clip is technically part of the original filter unit. No sweat though as the new filter comes with a new retention clip already on the male end and it is made to hold that line up in that female connection once you snatch than old inner 4-prong clip out.. NOTE new plastic one ONLY HAS TWO PRONGS and not four. The new male filter end neck may have even been longer than stock to get more space for future changes, but I was so pissed I can't say for sure because I honestly don't know what happened to the filter I removed...

The PROBLEM is due to BOTH GMAC CHEVY Vehicle design as well as poor aftermarket fuel filter removal tools out there from sale. And IT IS A GMAC Problem because your "normal" fuel filter removal tools WILL NOT FIT to get up in there and get a fuel filter off... And I mean who knows, perhaps GMAC has an entire procedure devoted to this that includes a custom dealer tool and that begins with back blowing all the remaining fuel out of that front line section from the Fuel rail pressure connector after first releasing the rear filter compression fitting. But you just don't stop to consider all this when you are just changing out some "Stupid old fuel filter"...

Live and learn and hope you don't die. I am just doing my part sharing so anyone that reads this won't...
 
#2 · (Edited)
I want to say one more thing about this matter because in my extended research there are guys out there making HUGE MISTAKES in their fuel filter replacement operations. So you can buy 3 shape-types of filters to replace this with... And here they are:

(1) I found some new replacement clones of the original out there for sale... HUGE MISTAKE..
(2) I found some new filters that look similar with the exception that they don't have the flared "base knob" welded on the front of the filter which thus SHOULD provide more access room to get the removal tool on that front side stem tube.
(3) Finally, I found some new filters that come with a plastic clip pre-installed on them. The magic trick here appears to be that NO ONE WILL TELL YOU that if you just snatch out that 4-way clip from within the female coupling connection coming off that front side line that you can use them as is with this nice easy new clip mechanism. So that next time removal should be a breeze as all you should have to do is compress the two sides on the plastic clip still protruding...

SADLY, I found several posts on amazon where people are telling folks to pull the new plastic clip off these new filters and shove that filter nozzle back up in that 4-way HELL TRAP... o_O GOOD GRIEF and back to square one for the next filter change.:(

BELOW is an excellent pic I found somewhere. It shows on the LEFT the new filter with the New Style WHITE plastic clip that came with pre-installed.. On the RIGHT it shows the female connection on the gas line going back up to the engine. What you are seeing is a pair of pliers SNATCHING THAT 4-PRONGED DEMON CLIP RIGHT OUT OF THERE, and so the new plastic clip can be used just like it comes on the new filter... Thus making the next change easier.. In theory at least.. :unsure: :)

Had I not freaked out and just powered my original filter out of there thus damaging that 4-way clip and pulling two prongs forward to see, I probably would have made the same mistake..

169418

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,
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Sooo,, Say NO to this one....
169420

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And SAY YES to this one...:
169419
169421


Just make sure it fits your vehicle before you go snatching out that internal line clip.. :)
 
#3 ·
I can attest to how horrible this job is on that model year.

Had to change this on a family trip with your aforementioned tiny plastic tool. We field modified one of the plastic ones to make it have longer, sacrificial teeth. One time use, but it worked.

Turns out it was a new filter we were arguing with, anyway. The mechanic who did it before marked the cross member with the mileage and we noticed AFTER 2 days working on it. 😑
 
#5 · (Edited)
:unsure: My memory does not go back that far any more...:rolleyes:

But if the Thread made sense and you are saying it would have helped then I am happy cause I debated writing on the subject at all... I honestly just did it for the SPARK Hazard Warning as I figure there's gonna be a lot of folks going after this filter on their own in the coming years. And every video I see out there talks about working that plastic removal ring in there with with a screwdriver as some point or other.. Then I wound up wondering if I put it back on right and started digging deeper -

I'm really thinking if I ever had to do that again on another one with the original filter still in there, I would just snip the front side off as close to the filter as a could and then just about any removal tool will get it. Hell you could shove teeth off an old metal rake up in there to free it at that point... With the filter cut off I bet even all the gasoline would run out to gravity and not have to worry about all that drippage out of the filter still attached. I can still smell that stuff on my arm if I think about it. Come to think that's all probably the GM Mechanic's PREFERRED METHOD.. LOL.

Anywayz thx for the kind word, and always take my writing with a large grain of salt... I am far from perfect..:)


But if you are going to stickle this look like it might work (NOTE how the bottom flat flange appears recessed back and cut out to avoid that flange on the top of the filter).

And NO you wont find it at Autozone...
169422

Still who wants to fork out 20bux and wait on shipping. But this might actually get it....

CONSIDER IT IS KEY to PUSH THE FRONT LINE REARWARD TOWARD THE FILTER and inseted TOOL when using this tool, and the internal line clip is already pressed up against the line flanged flare extruding ring. You cant just stick it in there and press the tool FORWARD.. So if you just try to put the tool in there and press it forward only, you are more likely to just hit a wall as the internal clip may be locked on the line flange somewhat.. . If you get the tool in there and THEN MOVE THE LINE REARWARD it will be more likely to open up...


Dun my duty once more I out....

@bbc
Where were you 2 years ago when I needed this information? 🤷
 
#6 ·
man, why would they have to change a perfectly good design? I thought I was guna have trouble removing to one on my 1997 burb, it looked like I was going to twist the lines and snap them off. but with 2 wrenches it came out in 2 mins without any problems. Gm does **** like this for assembly line purposes they dont care after that.

thanks for taking the time to write this up BBC! I'm also very glad that spark didnt start a chain reaction!

Just to add to your post, I have a large fire extinguisher that's rated for gasoline and I keep it within arms reach whenever I'm working with fuel. and remember to release the fuel pressure, I think theres a few ways to do that but removing the gas cap and the fuel pump relay? turn the key? I cant remember exactly but it's very important to release the fuel pressure.

Al
 
#9 · (Edited)
Yea WHY would you keep a classic line COMPRESSION connection on the rear of the fuel filter and then change the front out side tube to some kind a quick connect.??
  • Maybe they are/were beta testing the click-in connector ? Kind makes sense as they have now obviously rev'd that connector even further down from the initial 4-pronged metal clip, to OEM manu's making two pronged plastic insert clips...
  • SO they would not have done it on both ends it testing.
  • One thing for sure is the frame clasp around the fuel filter only provides support and does NOT prevent lateral filter movement.
  • Could just be that they like to SELL TOOLS...
  • OR perhaps they are using the quick connect for some kind of maintenance SAFETY purpose in which they don't have to risk an amateur mechanic bugaring the compression connection on that front engine line which would be much harder to replace. (its amazing how much young mechanics love to cross-thread and/or improperly seat compression connections -/ The value of a compression connection is just something that seems to ELUDE & torque young minds).
And that LARGE fire extinguisher you have better not be too large or you are going to have to have someone else there present to handle it and point it at you since your entire whole right arm, shoulder, and upper rt torso will most likely be on fire... LOL

And YES my arm was SOAKED. I seriously doubt a water hose would have put it out.

man, why would they have to change a perfectly good design? I thought I was guna have trouble removing to one on my 1997 burb, it looked like I was going to twist the lines and snap them off. but with 2 wrenches it came out in 2 mins without any problems. Gm does **** like this for assembly line purposes they dont care after that.

thanks for taking the time to write this up BBC! I'm also very glad that spark didnt start a chain reaction!

Just to add to your post, I have a large fire extinguisher that's rated for gasoline and I keep it within arms reach whenever I'm working with fuel. and remember to release the fuel pressure, I think theres a few ways to do that but removing the gas cap and the fuel pump relay? turn the key? I cant remember exactly but it's very important to release the fuel pressure.

Al
 
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#7 ·
My 2001 did not give me a hard time when I changed it around 150k miles.
1hr tops. Relieved pressure at the fuel rail.
I don't remember using a fuel line disconnect tool, just two fitting wrenches.
 
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#8 ·
I think it changes somewhere around 03...I'm assuming when the Silverado body changes, as that would make sense. My 04 Suburban has the devil's fuel filter and my 00 Silverado has one with double wrenches on each end.
 
#10 ·
This is not applicable to early 2001 maybe down to 1999.
I have flare fittings on both ends of my fuel filter.
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