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Gas leak at front of fuel tank

Number4

"I'm counting to 3, then I'm getting your dad."
Elite Explorer
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City, State
Woodstock, GA
Year, Model & Trim Level
04 Ford Explorer 4.6l
I have gas coming down the side and front (toward front of vehicle) of my fuel tank.
I removed the two shields around the fuel filter and dropped it down. Above the fuel filter is dry.
There’s a hump on the tank it appears, so it shouldn’t be coming from the fuel pump area, yet it doesn’t appear to be the fuel filter either.

It appears that the vapor system plugs into the tank just behind the fuel filter but on top. Maybe this connection?

thoughts?
 

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I have gas coming down the side and front (toward front of vehicle) of my fuel tank.
I removed the two shields around the fuel filter and dropped it down. Above the fuel filter is dry.
There’s a hump on the tank it appears, so it shouldn’t be coming from the fuel pump area, yet it doesn’t appear to be the fuel filter either.

It appears that the vapor system plugs into the tank just behind the fuel filter but on top. Maybe this connection?

thoughts?
I had a small fuel leak on a 2002 XLT 4.0. It was throwing a small evap leak code. It would actually drip on the ground with a full tank parked front low on my inclined driveway. Turned out to be a broken fitting to the evap canister on top of the fuel tank. Had to buy the entire hose from a dealership as the fitting was not sold separately.
 






I had a small fuel leak on a 2002 XLT 4.0. It was throwing a small evap leak code. It would actually drip on the ground with a full tank parked front low on my inclined driveway. Turned out to be a broken fitting to the evap canister on top of the fuel tank. Had to buy the entire hose from a dealership as the fitting was not sold separately.
I didn't notice the leak until I'd parked nose down on the lawn. How did you determine the source? I just filled up the fuel tank and would prefer not to have to drop it if possible...
 






I didn't notice the leak until I'd parked nose down on the lawn. How did you determine the source? I just filled up the fuel tank and would prefer not to have to drop it if possible...
It was 10 years ago, but as I recall I released the fuel tank straps and let it drop slightly and rest on the drive shaft. With a flashlight and contortions I was able to see the broken fitting. In my case it was the one that came out of the front of the charcoal canister made two 90 degree bends and went to the rear of the vehicle. I tied a string around it when I pulled it out so I could fish the new one back in without dropping the fuel tank completely.
 






So you didn’t drop the cross member that the trans sits on? The front of the fuel tank is resting on it. I can drop the rear of the tank as much as the hoses and wires will allow.
 






So you didn’t drop the cross member that the trans sits on? The front of the fuel tank is resting on it. I can drop the rear of the tank as much as the hoses and wires will allow.
Correct. I did not drop any crossmember. Keep in mind mine is a 4.0L, so there may be some differences in the fuel systems. A mechanic's mirror may help you pin point the source of the leak.
 






Well, the circled doo-hickey appears to be cracked. Not just a hose connection and I’m guessing this part isn’t available by itself....

Have to get whole tank. Dealer doesn’t have it. Don’t see it aftermarket. Try to find one at a wrecker that doesn’t have a hole in it?
 

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Wow that's tough. Hope you find the part. Still a big hassle.
That's something I worry about ... being unable to get a part.
I don't understand how old cars at car shows are still around and run.
How can they keep 50 year old cars running and we're having trouble getting parts for 16 year old cars?
 






New to me tank, $35. Some of the smaller wreckers don’t poke holes to drain them.

Should I fill it with water to make sure not doesn’t leak, before using it?
 

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Sure. Easy to check, before you do the repair work.
 






So, used gas tank has a gouge in the outer layer. It appears to have exposed the inner layer. About the size of an eraser head.
Use a 2 part epoxy to fill it?
Contact the yard for a refund and hope they have another?
 

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So, used gas tank has a gouge in the outer layer. It appears to have exposed the inner layer.
Use a 2 part epoxy to fill it?
Contact the yard for a refund and hope they have another?
 






So I thought if I disconnected the fuel filter to engine hose that I could siphon the tank of its 22 gals of fuel. But no luck. When I prime the pump a little comes out then it stops.
If I crank it comes out, but I don’t want to keep cranking.
Siphoning is not working. How best to drain this thing?

jump 3 to 5 on the relay?
Tried, doesn’t work...

Update:

While this does supply power, there’s still a signal from the pump module that is required. Dman
 

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I'd try to trade tank for a good one. If not successful, use your epoxy method.
Can you simply drive until gas runs out?
 






It was leaking pretty bad and getting worse. After disconnecting the cursed fuel filter, I used a plunger style hand pump and got about 18 gals out.

But now I have to fight the rear driveline bolts in order to get the tank out. #WhatsNext
 






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