Fuel cap seal

Hi folks,
I’ve got a leak from my fuel cap, only happens when I’m on a full tank or on a sideways slope.
I’ve tried to find a replacement seal but unless I’m searching for the wrong thing, I can’t find anything.
I got a cheapo complete cap from eBay and that was even worse so I’m back with the original one now.
Any suggestions or links to what I need?
1996 300tdi 90

Cheers

Is your vent pipe OK ?

I think this is the seal ...

Ditto on the vent pipe. Is it defo the seal and not corrosion on the neck of the pipe ?

Thanks for that link, i found that before but because it says early defender i passed but i guess mine is still classed as early with the tank under the seat.

I thought it was coming from the tube/neck to start with but i parked it on a slope last weekend and gave it a good wipe around and there was diesel dripping from the cap then running down the neck onto the body work.

marc.postle said:

Thanks for that link, i found that before but because it says early defender i passed but i guess mine is still classed as early with the tank under the seat.

I thought it was coming from the tube/neck to start with but i parked it on a slope last weekend and gave it a good wipe around and there was diesel dripping from the cap then running down the neck onto the body work.

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Try turning the existing seal over !! You could also use the seal as a template to cut a spacer out an empty plastic oil can or similar. Put that behind the seal to pack it out slightly.

meego said:

Try turning the existing seal over !! You could also use the seal as a template to cut a spacer out an empty plastic oil can or similar. Put that behind the seal to pack it out slightly.

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Now thats a good idea! i wish i hadn't launched the new cheapo one in the bin out of frustration now because i could of taken that seal off and double stacked them.

How full are you filling it ?
I tend to put max 45ltrs in (I think the tank is 55ltr) along with 200ml of 2 stroke oil (recently I are been smellin like a chainsaw).

marc.postle said:

Now thats a good idea! i wish i hadn't launched the new cheapo one in the bin out of frustration now because i could of taken that seal off and double stacked them.

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It might have been too thick and it wouldn’t have located fully for the lock. If you use it. Let me know if it works

Another one you can try is to slightly bend up the tabs on the steel plate to tighten the fit, if you are careful you can do this on the cap but it is easier to unscrew it.
At the risk of being shouted at this is a well known defender quirk and they all do it. It doesn't make it right and it can be rectified with some fettling but they do all do it.

i finally have an update on this.
I took the cap apart and flipped the seal like meego suggested and i also tweeked the taps a touch as dag019 said and its been fine since.
Yesterday i finally saved up enough money to completely brim the tank then went off road on a few steep banks and such and when i checked the cap afterwards, it was dry as a bone!

Thank you all!
On to the next issue now...............

Have to try that on mine, just have not been filling right up for a while.
Marc.postle, better treat that corrosion now there is no diesel limiting it.

tottot said:

Have to try that on mine, just have not been filling right up for a while.
Marc.postle, better treat that corrosion now there is no diesel limiting it.

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I have done a lot to this in the last 6 months of ownership and i still have a fair bit more to do and the body and repaint is last on the list. my guess is spring next year.
I have a few areas like that on various panels, some will get repaired, some replaced but i an planning on giving these areas a rub down and finding a treatment in the next few weeks to stop them getting any worse