replaced two different trunks fuel tanks due to Rust

[DPForumDog]

My guys are scratching their head. We have two different trucks in the past 3 months need new fuel tanks because they were so rusty.

2006 International 466DT fuel tank replaced for $2800
2008 F450 6.4 L fuel tank replaced for $1800

Yesterday we took our 2008 F450 in for an oil change and routine maintenance. We had no hint anything was wrong as the truck had been running fine. The mechanic called us back and said that we had so much rust and gunk in the fuel filter that the mechanic said the filter is coming apart. We cant look down in the tank like we do on our internationals.

In the 35 year we have been in business we have NEVER before had a problem with a fuel tank rusting out and we have always driven old trucks (normally International 4900-4300 and F450s)

Is this just a huge coincidence that two of our four trucks have had to have new fuel tanks due to rust problems.

What are we doing wrong? What caused this?
Why do fuel tanks rust out? I read that we should have caught the issue when we changed previous filters.

What can we do to prevent future problems?

Thanks for any all help, ideas, and suggestions .

Granny DP
DPForumDog
tag: rust in rusty rusted fuel tank diesel

 

[BigPapa]

Ford has had problems for years with their metal tanks delaminating. It looks and feels a lot like fine rust particles.

I work at the Nashville Schools bus garage and when I came to work here they were using BG Products #247 DFC (Diesel Fuel Conditioner) Plus Easy Treat in all the diesel vehicles we have with metal tanks, school buses, box trucks, maintenance trucks, etc. From what I’ve been told by the BG Products rep that comes in our shop, when the EPA transitioned us to ULSD the aromatic fluorocarbons present in LSD were removed. These chemicals were a “natural anti-corrosion package”. With these chemicals gone the tanks started corroding or delaminating.

I know the general feeling around here about fuel additives but for what it’s worth, we have had no issues with corrosion or delamination in any of our vehicles since I’ve been here. When I worked at a diesel pickup repair shop several years ago we stocked three of the Ford tanks at all times. We replaced a LOT of them.

 

[Tuesdak]

With the filter coming apart you may have bugs in the fuel.

Here are some pictures and I assure you that it's not rust even though it looks like rust.
https://www.turbodieselregister.com/threads/248698-ULSD-and-Biodiesel-Exposed!

 

[BDaugherty]

I have also dealt with a large number of tank problems. Mostly steel tanks, but also some aluminum. Fortunately, a radiator shop nearby my shop does great work cleaning and re-lining steel tanks and just cleaning the aluminum ones. Sometimes it's cheaper to get a new tank and usually faster, but most of the time cleaning and lining is the best deal. Just a week or so ago, I did two 150 gal aluminum tanks tanks off a Freightliner that sat for a few years. The fuel had turned to varnish and trashed the injectors right through two fuel filters.

 

[EDankievitch]

The Ford dealer by me has a stock pile of bad fuel tanks due to the de-laminating issue. The problem seems to be worse since ethanohl (sp?) has been added to our gas. Diesel tanks are not immune add a little bit of water an even though it may not show up in your water sep it's still in the tank, now you've got rust. This has been a huge problem for us in the marine industry. That's why the trend has been to go with plastic tanks like we have on our RAMs. The National Marine Manafactures Accoc says that since plactic tanks have entered the market there has not been a tank failure. However all metal tanks will fail at some point. I've seen fuel tanks on boats that looked brand new from the outside and were full of pin holes, all rotted out on the inside. Thanks EPA for the ethanohl.