fuel tank leak | Ford Explorer Forums

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fuel tank leak

Joined
May 17, 2016
Messages
16
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City, State
seymour,TN
Year, Model & Trim Level
1994 ford explorer xlt
hello i am new to this forum i have just bought a 94 ford explorer xlt 4x4 it has the 4.0l sohc v6 , my question is i filled the tank and when it was full there was raw gas coming from the top front of gas tank not the filler neck but the tank, how hard is it to remove the tank what tools do i need and is it safe to drive with it leaking thank you
 



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Are you sure it's not the gasket for the fuel pump/strainer assembly? It's not that hard to replace, but you will have to drop the tank to do it.
 












not sure?

im not sure but when i filled up yesterday gas just started pouring out lost about two or three gallons of gas before it stopped
tank is full
 






im not sure but when i filled up yesterday gas just started pouring out lost about two or three gallons of gas before it stopped
tank is full

It is not safe to drive as is. Dropping the tank is one of the hardest jobs to do, and there is no real way to know exactly which tools you will need. You will run into problems along the way. For sure you will need basic tools like ratchet and socket set, wrenches, hammer, etc. You will more than likely need an impact gun, angle grinder (not safe with gas nearby, but will probably need to grind a few bolts when the tank is out). You will need to somehow empty the tank, and will also need a jack to lower it and raise it. I would replace the whole sending unit with new fuel pump while in there. Also, when the tank is out, cut an access hole under the rear seat. There is a thread on how to around here. It will save you later on. You will also need quick connect fitting removal tools. The harbor freight aluminum ones are some of the best. I'm not certain what could be leaking. I'm guessing either the sending unit/gasket, the filler hose, or maybe the tank is cracked, but I doubt that.
 






It is not safe to drive as is. Dropping the tank is one of the hardest jobs to do, and there is no real way to know exactly which tools you will need. You will run into problems along the way. For sure you will need basic tools like ratchet and socket set, wrenches, hammer, etc. You will more than likely need an impact gun, angle grinder (not safe with gas nearby, but will probably need to grind a few bolts when the tank is out). You will need to somehow empty the tank, and will also need a jack to lower it and raise it. I would replace the whole sending unit with new fuel pump while in there. Also, when the tank is out, cut an access hole under the rear seat. There is a thread on how to around here. It will save you later on. You will also need quick connect fitting removal tools. The harbor freight aluminum ones are some of the best. I'm not certain what could be leaking. I'm guessing either the sending unit/gasket, the filler hose, or maybe the tank is cracked, but I doubt that.

+1. I don't know about cutting an access hole but do yourself a favor and empty the tank before beginning. makes life a whole lot simpler. figure gas weighs somewhere round 8-10# per /gal and gets heavy fast, even with jacks.
 






thank you all for your replies i will try to empty the tank before i start
 






My 1994 tank developed a similar leak but I caught it before it poured out as you indicated. I had the dealership replace it back in the late 1990s. Turns out a ball-peen hammer was left on top of the plastic tank most likely for years. With the normal shake of driving, It wore a hole in the top of the tank and only leaked when full. I looked for the receipt but couldn't find it. That hammer cost me a lot. The mechanic gave it to me as a souvenir.
 






i am hoping not to find a hammer i am hoping it is the gasket
 






FWIW, water is about 8 lb./gal. Gasoline is around 6 but with around 16 gallons left in the tank that's still about 100 pounds plus the weight of the tank. With a known leak, I'd think twice about doing it myself.
 






FWIW, water is about 8 lb./gal. Gasoline is around 6 but with around 16 gallons left in the tank that's still about 100 pounds plus the weight of the tank. With a known leak, I'd think twice about doing it myself.

You do what you have to, but I agree. This isn't a simple job.
 






the problem is probably the grommet around the check valve dealer only for about 8 bucks.
 






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