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Tank leaks when full

Last modified: Aug 12, 2006

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| Fuel Tank Repair 12Aug06
Repair cracked fuel tank using Loctite 406, 770 primer, and polyethelene sheet

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Tank leaks when full

Last modified: Aug 12, 2006

More evidence

Last modified: Aug 12, 2006

1: Remove Floor

Last modified: Aug 12, 2006

2: Reveal fuel pump, level sender

Last modified: Aug 12, 2006

Remove filler lines
Note the vent line is removed at the filler neck. Bag with zip tie will keep the spills to a minimum.

Last modified: Aug 12, 2006

Remove pump lines
and electrical connectors at the level sender. Regular household pliers work well pulling the pump lines. Cover the holes with tape. Update: spray some wd40 in the holes an hour or so before pulling the lines and have new orings ready.

Last modified: Jun 14, 2011

Tank dropped
Remove the nuts on the straps. Having something to catch the pump like a hydraulic jack with a board on top, or some 6"x's is helpful.

Last modified: Aug 12, 2006

It's a girl
The crack on the right concerns me, I hope the tank strap doesn't break my repair.

Last modified: Aug 12, 2006

Special Tools
Carb cleaner, 120 grit sand paper, loctite 406 glue, loctite 770 primer, 0.03" polyethelene sheet cut into way too many various strips. The last three items came from McMaster Carr.

Last modified: Aug 12, 2006

Clean the area
I used carb cleaner followed by some window cleaner. I sprayed on the rags to avoid getting any in the tank.

Last modified: Aug 12, 2006

Sand and prime
Sand it all up, then spray or wipe on the 770 primer.

Last modified: Aug 12, 2006

Patched the easier one
Sand, prime and glue the patch. Use uniform pressure to hold it on until it sets up, about 2 minutes or so.

Last modified: Aug 12, 2006

Patched the second one
I'll add some more material next to this one for the strap to pull on.

Last modified: Aug 12, 2006

Washer Bottle Repair
The same basic procedure also works for washer bottles. This is from my '97 900.

Last modified: Aug 27, 2008


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