Gas Tank Replacement Options for Gen II GTS

[drewsss]

Luis V had an excellent write up for replacement of his Gen II GTS fuel tank, due to a leak at the gas tank filler neck area.

I may be facing a similar issue, but don't want to rip out my stereo and then cut a hole in the back to pull out the gas tank and replace it.

I know that Luis tried an epoxy/RTV mixture to seal this leak, but it only lasted 3-4 months. Has anyone had long-term success with a different kind of adhesive (perhaps an aerospace-grade adhesive, such as one described in the link below)?

http://www.ppgaerospace.com/getdoc/5...l-Sealant.aspx

Moderator - please feel free to move this thread to wherever it belongs, but wanted to start here. Thanks, Drew

[dave6666]

You can put the tank in now, or wait to put the tank in later after your patch fails. But you will be putting the new tank in.

BTW, I have a guy that welds the tanks i.e. crack repair. Very simple permanent repair if done correctly.

[ICPREY]

I've never used that sealant on a plastic tank, but I use it quite regularly on helicopter fuel tanks and cells(metal components). If you could create a patch that has a metal outer edge (both on the tank and patch) and then used the sealant to wet install and sandwich it all together then it would probably hold. It may not be possible or worth the effort if it's on a contoured portion of the tank.

[SnakeWatching]

How about trying "Flex Seal" the paint-able rubber? I wonder if that would stop a gas leak on a tank? (and stay flexible). FORGET THIS - says cant be used near gasoline.

[Martyb]

I researched this before I replaced my tank last year Drew, I was told the only way to possible fix it long term would be to repair the tank from the inside. I decided to just put a new used tank in. It's really not that difficult. I'll be back out there next month if you want an extra set of hands.

[drewsss]

I researched this before I replaced my tank last year Drew, I was told the only way to possible fix it long term would be to repair the tank from the inside. I decided to just put a new used tank in. It's really not that difficult. I'll be back out there next month if you want an extra set of hands.

Thanks, Marty - may take you up on that (when it cools off, of course!) Where did you get your tank from..?

[MH60M]

In an extreme case, I'm sure the filler neck fitting can be replaced with AN style fitting or bung without cutting out the tub. Might be something to look into. Much larger fittings are used on aircraft in the same manner.

[Camfab]

In an extreme case, I'm sure the filler neck fitting can be replaced with AN style fitting or bung without cutting out the tub. Might be something to look into. Much larger fittings are used on aircraft in the same manner.

That's an interesting idea, even if you had to pull the tank. Clearly replacing the tank is a short term solution if they are all sourced from an inferior supplier as is so common with Chrysler.

[drewsss]

Oh joy. Took off the wheel and lining, took a looksie, and got the final diagnosis. Broken filler neck.

Fuel tank and close up panel have been located and ordered.

A copy of LuisV's surgical instructions have been also printed and placed into a binder for reference.

It will be a ball cutting into my custom stereo system, and then cutting some more to access and replace the tank.