Engine/Transmission (1994 - 1998) Fuel leak

[Dick R]

Just noticed fuel dripping from under the fuel tank , got a flashlight and mirror to see where it was coming from and noticed it was coming from on top of the tank at the sending unit , couldn't see the exact spot though , the fuel kind of sprays out toward the center of the truck only with the motor running , tried it with just the key on but nothing , I know the rotten tank has to come out but anyone know what it might be ? ( only happens in the winter )

 

[DBentley]

My 96 did the same thing last year in 10 deg. weather. It could be just a line but mine was a rotted metal elbow at the top of the fuel module. Since there was a full tank and 3 inches of ice on the ground I cut a 7 or 8 inch square trap door in the bed just over the tank module and put some hinges on it to have easy access later. (because this module is junk)Tryed to fix fuel module but it was built to be disposable so my local 5 star dealer got me for about 250. 00 dollars and the install was very easy except for the cheasy plastic hose clips.

 

[tp0d]

Sounds like the steel return line has rusted thru at the elbow just as DBentley said. Mine is seeping, I`m dreading dropping the tank in this cold without a heated garage. sigh... figures it leaks when its cold out. .



Found a module from a 97 on ebay for 24. 50+ship instead of 250$. http://cgi.ebay.com/ebaymotors/97-D...004QQitemZ140068826924QQrdZ1QQsspagenameZWDVW



If my lines are rotten at the module, I will be replacing them with all new alum lines. Its nice to be a plumber hehheh



good luck



-j

 

[Dick R]

has anyone posted a procedure on removal of the tank ? I haven't found anything yet on this site , I was able to siphon out 20 gals but it stopped flowing so maybe elevating the front and try again , looks to me like a problem stabilizing the darn thing when removing I have a floor jack but ?

 

[Champane Flight]

I used a couple of 2X4s

Used my transmission jack adapter on my floor jack and a couple of 2X4s the length of the tank, strapped them with some nylon tie downs. I still had around ten gallons in tank. The hardest part for me was disconnecting and connecting the lines and electrical with the tank down a few inches. A lot of guys just pull the bed, or cut a access hole as said above, it may be easier...

 

[Dick R]

using the transmission adapter sounds good I have one also , were you able to do this work with the truck on all four or did you have to jack it up on to jack stands ?

 

[Champane Flight]

No stands

using the transmission adapter sounds good I have one also , were you able to do this work with the truck on all four or did you have to jack it up on to jack stands ?

I was able to slide the tank off the jack once it was down, then out the side. The trick is getting it back on the jack afterwards. Got my neighbor to help me slide the jack under it again after lifting one end. Mine is just a two wheel drive, I am sure a 4X4 would be easier. .

 

[Dick R]

if a person got the tank off slide it out and than drain it before reinstallation it shouldn't be to hard to handle than ? or is the darn piece of plastic heavy anyway ?

 

[Champane Flight]

Not heavy

if a person got the tank off slide it out and than drain it before reinstallation it shouldn't be to hard to handle than ? or is the darn piece of plastic heavy anyway ?

Just awkward, I still had a few gallons in it after tilting, siphoning, and wrestling around.

 

[MAleksandrowicz]

I recommend pulling the bed off the truck. It sounds like a pretty involved task but is really not bad at all. I helped another tdr member take his long bed off and we did it in less than 2 hours. It was the first time doing it for both of us. Take the 8 bolts out, disconnect the taillight wires, take out the 3 screws for the filler next and lift it off.

 

[Dick R]

you know I thought of removing the bed but I have a fiberglass topper and a bed liner but the big thing is I also have all the fasteners ect for a fifth wheel hitch that is fastened to the frame , thanks , but , off comes the darn tank , are their any rubber hoses ect that should be replaced at the same time it is a 98 ? really don't care to do this again if I can prevent it .

 

[MAleksandrowicz]

I would replace the lines with rubber fuel grade hose. From tank to Lift pump and From Overflow valve back to the tank.

 

[Dick R]

these hoses that your refereing to , can these be bought from balk and cut to fit using stainless hose clamps ? thanks

 

[MAleksandrowicz]

Yeah for good fuel rated hose it is around 2 dollars a foot.

 

[Signal73]

Pick it up at west marine or boaters world. 5/16 return, 3/8 supply.

 

[Dick R]

Great I do have a West Marine near by , never thought of them , thanks

 

[AlFischer]

I got marine grade fuel line from West Marine. Be aware there are two grades of diesel rated line. I forget the actual number but it was thicker walled and costs almost $3/ft. I figure the thicker wall might last longer and my time and grief is wort more than the $1/ft difference.