Is this fuel tank fixable?

Tigerman

Tigerman

TJ Enthusiast
Ride of the Month Winner
Joined
Aug 31, 2018
Messages
384
Location
North Hills, CA
Hello,

I took the jeep out yesterday and did some wheeling. That part was fun. The not so fun part was the occasional smell of gasoline... Naturally, after I got home, I looked around. Sure enough, the bottom left and the left sidewall of the fuel tank looked like it was wet at some point and covered by fresh dust. See the pic.
20180909_083326.jpg

I did the fuel pressure release procedure, disconnected the battery terminal and after unbolting and unplugging, lowered the tank. Take a look at the pic below and please please tell me that the leaking seal/part is replaceable or repairable :))))). If it is not, then perhaps you know who sells a new tank? I sure hope I can fix that leak.

20180909_113133.jpg




Thanks
 
There is no seal to replace that one in the factory part diagrams. My guess is they would just want to buy a new tank.

However, that doesn't mean it could't be fixed. The real question is how (if at all) that seal can be replaced. I'm not sure that part is removable (is it?).

This is one more reason I switched to a GenRight aluminum tank. Not only does it offer more room for my rear axle / lift, but it's solid aluminum, so I don't have to worry about these sorts of things with seals, or other effects that ethanol might have on a nylon (I'm assuming it's nylon) tank over time.
 
Chris said:
There is no seal to replace that one in the factory part diagrams. My guess is they would just want to buy a new tank.

However, that doesn't mean it could't be fixed. The real question is how (if at all) that seal can be replaced. I'm not sure that part is removable (is it?).

This is one more reason I switched to a GenRight aluminum tank. Not only does it offer more room for my rear axle / lift, but it's solid aluminum, so I don't have to worry about these sorts of things with seals, or other effects that ethanol might have on a nylon (I'm assuming it's nylon) tank over time.
Click to expand...

Thank you Chris,

I also looked up the diagram and saw no separate part number for it. I was hoping that someone had a similar problem and figured out a way to fix it. The tank you linked looks awesome, and I have no doubt that it offers benefits over the stock one, but the price on it is also awesome, lol $1400!? I am afraid that is a little over budget for this TJ of mine. Are there any other alternatives, any other manufacturers that don't charge that much for a stupid tank?
 
  • Like
Reactions: Chris
I haven't seen an aftermarket manufacturer of TJ fuel tanks other than GenRight (which BTW, you can get them for around 20% off when they have their sales, the next one likely being Black Friday).

You could source out a used tank on eBay, probably find a leftover NOS (new old stock) tank from the dealer, etc. Hell, if you were closer to me here in Oregon, I'd give you my factory fuel tank with 50k miles on it for free.

Maybe someone here who has run into a similar issue will chime in on this and give better advice than I have, as I haven't run into this issue.

I'm a bit perplexed as to why that piece is separate from the fuel tank and not just one piece (the GenRight tank is just one piece in that area).
 
  • Like
Reactions: Tigerman
It's separate because it would be difficult to mold that into the tank. I'm sure its welded in. You might be able to re melt the plastic there, add some filler, and get it sealed back up. You'd need some filler material (polyethylene or polypropylene not sure what the tank is made of) and a soldering iron...
 
  • Like
Reactions: Chris
Chris said:
You could source out a used tank on eBay, probably find a leftover NOS (new old stock) tank from the dealer, etc. Hell, if you were closer to me here in Oregon, I'd give you my factory fuel tank with 50k miles on it for free.
Click to expand...
He's got a '98, and with yours being the later model ('05?), isn't all the venting/evap stuff different? I'd venture a guess that he'd need the earlier version of the tank.
 
Chris said:
I haven't seen an aftermarket manufacturer of TJ fuel tanks other than GenRight (which BTW, you can get them for around 20% off when they have their sales, the next one likely being Black Friday).

You could source out a used tank on eBay, probably find a leftover NOS (new old stock) tank from the dealer, etc. Hell, if you were closer to me here in Oregon, I'd give you my factory fuel tank with 50k miles on it for free.

Maybe someone here who has run into a similar issue will chime in on this and give better advice than I have, as I haven't run into this issue.

I'm a bit perplexed as to why that piece is separate from the fuel tank and not just one piece (the GenRight tank is just one piece in that area).
Click to expand...

Thank you so much Chris, that is a very kind offer!

I think I will attempt a repair after I get a few more pointers.
 
  • Like
Reactions: Squatch
Ranger_b0b said:
It's separate because it would be difficult to mold that into the tank. I'm sure its welded in. You might be able to re melt the plastic there, add some filler, and get it sealed back up. You'd need some filler material (polyethylene or polypropylene not sure what the tank is made of) and a soldering iron...
Click to expand...

That sounds a bit challenging to get it right. You don't think the epoxy resin they sell for fixing fuel tanks is good enough?
 
Squatch said:
He's got a '98, and with yours being the later model ('05?), isn't all the venting/evap stuff different? I'd venture a guess that he'd need the earlier version of the tank.
Click to expand...

You’re right. I missed that his was a 98. The 05-06 tank is totally different.
 
Might be...if you can get it into the hole. Gasoline is a pretty good solvent too. I don't know about the long term viability of epoxy. You would have to get it super clean for starters.

Tigerman said:
That sounds a bit challenging to get it right. You don't think the epoxy resin they sell for fixing fuel tanks is good enough?
Click to expand...
 
The only way to fix that leak is to use a hot air welder with polypropylene rod. Otherwise find a good used tank.
 
  • Like
Reactions: Chris
JB Weld Quik Stick could probably fix that to be honest. I've repaired some very interesting things with that stuff and it works amazing.
 
  • Like
Reactions: Xposure and Tigerman
I ended up using something similar to JB Weld. I cannot exactly remember the name but I think it was "QuickSteel" or something like that. It is an epoxy resin for plastic tanks in a form of putty that you kneed aggressively until it warms up in your hand and than apply. I put a lot to be honest, and all around that area and let it cure for 4 hours (it said at least an hour). It looks good! No smell, no leak, but only time will tell how well it will hold.
20180909_185738.jpg
 
  • Like
Reactions: KCsTJ, techster82 and Squatch
I just bought a new (used) tank because of that same issue.

I have access to sealant that is designed for aviation fuel. But in the end i just don't want to accept the risk that it will leak again and being close to the exhaust i really didn't want to burn my jeep up.
 
OK Tigerman!!

I think we need a reminder post every few weeks on it staying sealed. Hopefully we'll never get one that says it leaks again, but even then I'd to like know.

How much prep work did you do before applying that stuff? I don't know what should have been done but if I ever ended up doing something like that I would have been temped to drill some 1/4" holes to let the JB-like stuff to fill in to help keep it there.
 
Top Bottom
Back