2nd Gen Non-Engine/Transmission Fuel leak

[rjones]

My tank is leaking fuel... I crawled under and its coming from the top. . mid tank... was there any probs with lines rubbing in dodge trucks? or has anyone else had this prob?.....

 

[dblake]

Did you top-off your tank. If so it will leak from the top. I only top-off when I'm going to get in and drive for a while right away.

 

[Joe G.]

It's probably the big nut that holds the fuel pickup and sending unit in the tank. Look over the frame and you should see a white plastic nut that looks something like a big fruit jar lid with knobs on it. You should be able to tighten it with a long piece of dowell and a hammer. If that does not work you can get another gasket for it and replace it. Big PITA of a job because you have to either raise the bed or lower the tank so you can take the fuel hoses off so you can put the gasket in the plastic nut.



I top my tank up completely in the neck. No leaks.

 

[rjones]

No I didnt fill it its less than half right now I want to run it low incase I have to drop the tank.....

 

[rjones]

I check the tank today and its not leaking when engine is off... . but I started the engine and its spraying fuel looks like at the line just going into sender module... . sooo my conclusion is new module... any input?

 

[Joe G.]

More likely a poor connection where the return line attaches to the module or a crack in the plastic fuel line. The pipe into the tank is just a piece of steel tubing right there.

 

[rjones]

yeh its coming from the steel line going into the module since its Sunday Im trying a temp fix until I can get a new module and have time to fix ill use fiberglass resin to seal the line for now Ive done it before with a gas leak and as long as its hardened it will last a while..... btw its leaking right at the area where the line goes into the module... . the stell line is rusted out...

 

[TMitch]

Had the truck idling while I was loading the ATV in the back tonight and after I was all finished I parked it in the garage and smelled diesel. I noticed a few drips of diesel on the middle of the tank... looks like I have the same problem here. Only half a tank and it doesn't drip when not running. Looks like I have to drop the tank... and I'm leaving on holidays tomorrow... right after I get home from work...

 

[CumminsPower98]

TMitch, on my cousin's '97 the return line rubbed the plastic protector on the top frame rail and wore a whole in it. Just another place to look before you start pulling stuff apart. I fixed this leak by cutting the line in two and coupling it back together with a short piece of fuel hose and then fixed the rubbing problem. I was able to do this without taking anything apart but it was a bit of a pain.

 

[TMitch]

I'm back from our vacation so here's the rest of the story... I went back out and fired up the truck and then crawled under and took a look. I just about got a spray of diesel in the face . There was a pin hole rusted in the metal through fitting (return line) on the tank module. Once I calmed dow, I cleaned it off and then got out the seal-all and gooped it all over the fitting. I let it dry over night and when I started it up the next day it seemed to be holding. So we left on holidays and had it fixed while we were on the road. Ended up replacing the whole module. I could have cut the metal fitting in half and slipped a short piece of rubber fuel line over and clamped both ends but it would have just been a patch job and who knows when the supply line might have gone. I never told my wife, I just said the truck was going in for "routine service". Picked up a BHAF as well, and chased my cousin out to his cottage. He was in his 2003 Duramax 1-ton. On a long hill we had to pass 3 loaded rigs and I had no problem keeping right on his tail. When we got to his cottage his was quite impressed that the 'old dodge' could keep up with his Chev. He immediately wanted to pop the hood and see what I had done under there. He was even more surprised when I told him all I had done was change the air filter!

 

[rjones]

yep thats what happened to me however i used rubber line and what a mistake when the fuel starts to thicken in cold weather the line collapsed so i have to fix before cold weather sets in... .