2000 gas tank plastic reservoir

[bigboy1]

I am in the process of replacing the fuel pump and sending unit in my 2000 Explorer and discovered a loose plastic reservoir inside the gas tank. The loose plastic reservoir is the part which damaged my original fuel pump and sending unit. Can this plastic reservoir be cut up and removed from the tank? Or does the plastic reservoir serve a function which is reqired?

 

[Jnieblas]

Hi Bigboy:

I had the same problem loosy reservoir and think this dameged my sending unit aswell.

Did you find any answer to this, I tried to push it to place it in place but no luck!!

Thanks.

 

[bigboy1]

My Solution

Jnieblas;

Thank you for asking. I have not heard from anyone who has the answer regarding the plastic reservoir. I live in the Detroit Metro area and have access to several automotive engineers. All of my associates are either GM or Chrysler engineers as I live in the northern subs. Most of the Ford people are in south and west burbs.

Apparently, most gas tanks do not have this type of reservoir. The thought is that the reservoir is intended to keep gasoline at the pump during high speed cornering, starts, abrupt stops, and rough terrain. While researching this problem and help for changing out the pump and sending unit on this site I noticed several pictures of Explorer gas tanks which did NOT have the plastic reservoir.

I ended up taking the tank to a local radiator shop that also repairs gas tanks and they had not seen many tanks with a reservoir in them. However, the ones they had seen were attached to the tank differently than this Ford tank. There were several options available to me i.e. new tank, used tank, reattach the reservoir using studs, all of which would have cost me $125 and up. The option I selected was to pay the shop $45 to cut up the plastic reservoir to remove it from the tank and clean the tank. Leaving me the options of replacing the tank with a used or new tank if I have any problems.

It has only been a few days since I replace all the parts and so far, I have not noticed a problem. I drive approximately 500 to 1500 miles each week and I should uncover any problems within a few weeks if any should occur.

I should mention the fuel pump and sending unit assembly also cost me $232 and a small amount for a tube of dielectric grease. Other than my dilemma of what to do about the plastic reservoir, I did the job myself and even on this 9-year-old truck in the center of the rust belt, I found the job to be relatively easy. Removal and disconnection took the most time, but reinstallation was very quick and easy.

I will also take this opportunity to caution anyone working with a gas tank to be mindful that while gasoline is not a flammable it is volatile and care should be taken when working with these parts. An empty gas tank is highly volatile and a spark or other ignition could be hazardous and cause bodily harm.

 

[Jnieblas]

Well after reading it, and almost cut it off.

I decided tu put it on place. my problem was that the fuel gauge was always on top saying full tank, I ran out of gas twice so I decided to drop tha tank, my thinking is that the reservoir was hitting the level or was trapped keeping the level on full position.

I tested manually in different positions turning key on and off and worked just fine.

Any way yestarday I did 4 cuts to the reservoir at the bottom where it sticks to the tank, with this 4 cuts I can flex and press the reservoir so finally Success.

I had it on place!!! Hope stays there forever heheheeh.

Now I want to test the level itself I mean the foam, merge it on water to see if it floats!!! this is for today. maybe on weekend I put everything back to the Sportrac!!!

 

[gijoecam]

I'm an engineer, and I work for Ford (though not in an engineering capacity), so I don't exactly fit the criteria, but I can do one better: I worked production in the Dearborn Engine and Fuel Tank Plant where those tanks were built. I spent many a long hard night on that line...

If my memory serves, that tank's reservoir was tack-welded in-place before the two halves were seam-welded together. There was a thin plate on the bottom of the reservoir, and a small tube. My thought is that it served two purposes: First, it helped prevent the pump from running dry when parked on a hill, cornering, etc. The second is that it provided a 'bath' for the return line to dump into, helping to keep the pump assembly cool.

Is it absolutely necessary? Probably not. However, the F-150, Expedition, Fox-platform Mustangs, and the Crown vic, Gran Marquis, Town Car, and Escort of those times all had them. The pre-97 F-150s didn't, the Mark-VIII didn't, and the E-150s didn't... I have no idea why. I wouldn't think they would take the time or expense to put them in there if they didn't serve a purpose though...

 

[bigboy1]

Plastic Reservoir

GIJOECAM;

Thank you for your reply. I saw your user name and several of your comments previously regarding a similar matter while I was researching this site for my problem. I found your comments to be helpful in deciding what to do in my dilemma. In fact I have thought to myself several times over the past few days how nice it would be to hear what your thoughts are on this matter. I thank you for taking time to respond to this posting.

As you can read from my prior comments I finally elected to have the reservoir cut up and removed from the tank. In my tank the plastic reservoir was secured to the bottom of the tank by way of an oddly shaped cutout in the bottom of the plastic part through which the metal tank had been stamped with a similar shaped die and secured the plastic reservoir to the metal bottom by way of a pressure fit. The guy at the radiator shop mentioned that he had not encountered this type of assembly and that he typically saw the reservoirs attached by way of metal pins through the plastic, a method mentioned by you in your posting.

One consideration I discussed with the guy at the radiator shop was to drill holes through the bottom of the tank and bottom of the plastic reservoir then put a metal stud or bolt through the holes to secure the reservoir in place. The guy said the studs or bolts would also need to be soft soldered to the metal tank to keep the tank from leaking. By the time he would have finished the job correctly it was going to cost much more than a used tank would cost and was approaching the price of a new aftermarket tank.

Sometimes it is a shame that anything can be done with enough money, but the solution always seems to come down to the smallest amount of money; even the space shuttle.

 

[gijoecam]

OK, my memory has failed me again... I thought it was the F-150s that had the reservoir stamped in place, but it was the Explorers... I had a 50/50 shot. (I used to love loading those reservoirs on the line... it was one of the easier jobs LOL!)

The stamped-in-place units were pretty durable. (I used to have to periodically yank one off to ensure they were held in place properly... it took a crowbar to do so, and mangled it in the process) If yours came off, it's probably because it was never properly in place to start with. To my knowledge, the Explorer tanks were the only ones that were stamped in place like that. I believe it was because they tried to move away from the tack welds or studs since welding to the tank removed the coating on the steel in that area, creating a potential corrosion point. Seemed good in theory, but apparently had its own set of pitfalls.

Hope it wasn't one of the tanks I built that year....

-Joe

 

[CDW6212R]

Interesting stuff, and I have not seen one of those reservoirs yet.

BTW Joe, how far back did you work on the Explorers? Did you by chance see the 94 and older models? I'm wondering if anyone closely compared the old 91-94 4dr. tanks to the 95-01 Sport tanks.

I bought a 99 used Sport tank to use with a big Expedition transfer case, and a shorter tank is required. I had my old 93 4dr. tank still, and setting close by I noticed they are similar. The 91-94 4dr tank is the same short length as the 95-01 Sport tanks.

I'm about to try to affix the sensors to the early 93 tank, and install it in my 98 truck. I like the old plastic tanks. It was interesting to see that the plastic tank holds more gas given the same outer dimensions(including external seams). The later metal tanks have the very large seam on the outside, which takes up space. Meaning they are actually smaller, but the seam included makes them take the same space as the old larger tanks. Odd stuff yes,

 

[Jnieblas]

After 4 days with the plastic reservoir put back in place!!!!

My fuel gauge is working perfectly!!! No acting Up.

So, I read about gauge malfunctioning, Harness even bad sending units.

Mine was just a loosy reservoir that hitted my sending unit.

Now will focus on different issues on my Sport trac.!!!