Fuel tank leaking

sitrials · Posted: Mon Nov 16, 2009 6:05 pm Post subject: Fuel tank leaking

My fuel tank has sprung a leak on my 90 300tdi.
It seams to be leaking from where the thicker part of the tank (guard?) meets the tank its self could it have rusted through or could it have cracked?

Anyone recommend where to get a tank from if required? I've looked at paddocks but there is so many
I'm going to try and drop the tank out tomorrow, its too dark now.
I've just drained it as i only filled it sunday! this may explain my poor fuel economy!

blanche_90 · Posted: Mon Nov 16, 2009 6:39 pm Post subject:

they tend to go on the seam when you give em a bit of a wack or rust expands in the seam opening it up slightly.
crud can get trapped between the guard and quite happly rot away the tank unknown till it's to late.
when you get your new tank try to seal these gaps with a few extra coats of paint.
also be awere that the tank out rigger may start to fall apart when you come to remove the tank.

sitrials · Posted: Mon Nov 16, 2009 6:59 pm Post subject:

from what i've been reading its right royal pain in the posterior!
Which tank from paddocks/lrseries do i need? I will order it now as it seems its gone at the seam

blanche_90 · Posted: Mon Nov 16, 2009 9:07 pm Post subject:

if that's your landy in your aviter, then it's a standed 90 tank.
tell em what it is, petrol/diesel, age etc. Idea

you may also req a new filler pipe if the clips are all rusted up and you have to cut it off. Crying or Very sad

new gaskits for the sender and fuel return pipes and possibly thier relivent set screws. Rolling Eyes

what ever you do, DON'T try welding the tank. Embarassed

that tank is bigger than it first looks, it's possible to do on your own, but it's a lot easer with two of you. Razz

rainbird · Posted: Tue Nov 17, 2009 7:09 am Post subject:

The "funniest" bit I found when replacing mine is that they obviously installed the tank in the chassis before putting the body on in the factory as all the clips holding on the hoses had been put on from above. Right royal PITA to get them off!

As a short term solution, you can rub soap in the seam to stop any leaks - until it rains anyway, but at least it's not dripping out on the drive

sitrials · Posted: Tue Nov 17, 2009 6:09 pm Post subject:

OMG!
how hard is it to get a tank out?
struggling with the bolts labeled 11 they are completely rotten! any help muchly appreciated!

Ray_Jnr · Posted: Tue Nov 17, 2009 6:43 pm Post subject:

hahaha... i did my holed tank a few years back, took me 3 days. to get those off i used a hacksaw blade with one end wrapped in ducktape as a handle.

bertie_bas205 · Posted: Tue Nov 17, 2009 7:13 pm Post subject:

I did one on my 90, a royal pain in the hoop.....

Didn't put it back in, bought a fuel cell instead..... Wont get damaged in the back...

Bertie.

Oshodisa · Posted: Wed Nov 18, 2009 10:53 am Post subject:

I did mine a couple of years ago. If I remember correctly it was the first major job I did on it!!

Pain in the ass - yes

Worth it - yes

I think I took a combination of a Dremel, hacksaw and hammer to the bolts as mine where shot as well. the brackets were fine though.

The getting it out and the new one in is all in the twist and lift (sorry I cannot remember what angles I used!!).

The job took me a weekend which was one day swearing, skinning knuckles, dropping grit and rust in my mouth and generally not getting anywhere. The next day I got under the truck expecting the same and 'pop' I got it right first time!!

My best recommendation is to take your time, have a brew when things are not working and you never know - you might get it right next time!!

terence · Guest

an air hacksaw.

i dont have one, but when i last did this i wished i had.

taking the floor plates out helps with the gymnastics routine.

sitrials · Posted: Wed Nov 18, 2009 6:57 pm Post subject:

tank is finally out, combination of grinder, reciprocating saw, hammer and sharpened piece of 6mm steel.
tomorrow will be swaping the sender unit and inlet and outlet pipes. any tip of taking the lock ring off the sender unit or it easier than it sounds i haven't even looked at it yet!

Ray_Jnr · Posted: Wed Nov 18, 2009 8:42 pm Post subject:

whack the locking ring in an anti clockwise direction with a flat headed screwdriver and a hammer Cool

sitrials · Posted: Thu Nov 19, 2009 9:46 am Post subject:

can anyone tell me the correct size for the jubilee clips on the large main hose?
I can get some from work but forgot to measure it, and i'm not back at work till monday after 4pm today.

jdixon7 · Posted: Thu Nov 19, 2009 1:05 pm Post subject:

Hi

When I put a new tank on my RRC, I cut the old tank in half and used it as a guard as the bash plate does not protect the sides of the tank.
Right pain putting it plus the bash plate on but worth it.
It also means the drain plug is now recessed.

John