Hi guys, everytime I fill my tank (and I stop when the pump stops, don't overfill) I have this bad gas smell around the filler/tank area that goes on for days.

Had to have the vehicle towed reciently and when the guy raised the front of my truck to get it on the flatbed, gas started coming out of the back end!! The tow truck said "yea, typical explorer, they all do that"... Huh?

Anyone heard of this before?

The fuel pump sending unit located within the fuel tank has 2 metal lines that exit the tank and attach to the vehicles stainless steel fuel lines. These sending unit lines are not stainless and will eventually rust out and begin leaking fuel.

Also the metal ring that holds the fuel pump in might have started to rust out. My brother had that problem and everytime he would put the truck in park when it was running, a big puddle of gas would leak on the ground. So I'd advise having that checked too.

Anybody ever heard of a first gen gas tank cracking? Was just told by a local dealer that this is a common problem and he can't even get any to sell! Sounds fishy to me. The plastic material they're made of should last forever, as opposed to metal. He said plastic has a tendency to deteriorate. I'd say if that is the case, then the factory would cover the replacement, as it would definetly be a safety issue.

I haven't heard of the plastic tanks cracking.. However I have heard of the embedded lock ring flange connector rusting apart... Basically the tank is plastic except for a steel mounting flange embedded into it while semi molten at the factory. If this rusts out then most shops will require you to find another tank ($$$). If this were me I would find some fuel resistant sealant or epoxy and glue a new fuel pump and sending unit down.

Well, got it all fixed. It wasn't as bad a job as I had anticipated, only to try and avoid getting soaked in the water puddles left on the floor under the truck after last night's snow melted off and dodging the falling RUST. Didn't want to leave the truck inside overnight. That would have been the sensible thing to do, but with an attached garage you have to be careful with fumes, especially gas, as I found out when the leak was discovered. Had to vent the whole house for a time (not too practical in Jan. in Ohio).
Ya, it was the ole rust bandit again, chewing into one of the fuel pump lines. It broke off right at the metal plate. Got it back on the road for about $120.(pump, locking ring and filter). Hate to think what it would have cost to have it done somewhere :fire: especially a dealer $$$. Some guys I work with say that I'm crazy for crawling around under my truck especially in the winter. They'd rather just pay someone to do their work. I feel, as long as I'm able to do it, I'll keep doing it. It sometimes gets frustrating, but its a feeling of accomplishment doing it yourself, and its a learning experience.
I'd rather take the money I saved and add it towards my future retirement house in Vegas :cool:! Thats what I'M talkin' about!
Thanks again for the info...this site has been a great help over the last 150 thousand miles. Still looking to turn 200k this year!

:thumbsup: Congrats on replacing the fuel pump.. The satisfaction of doing it yourself is a great feeling. When I replaced mine in my driveway several February's ago the dealer wanted $450 so you saved yourself a nice chunk of change...