Need To Replace My Fuel Tank

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Robert Wagner

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My 2000 Expedition 4.6L XLT 2WD isn't holding pressure (evap system is unhappy) as tiny cracks have formed in the 21 year old plastic tank. Not to the point where liquid gas finds a way out... only vapors.

Shop says I need to replace the tank but the tank is no longer made. Apparently my only option is to find a NOS one or roll the dice on a pull from a junk yard.

Has anyone found a source for a replacement tank?

Thanks!
 

Trainmaster

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If you have a local rebuilder of tanks, you may ask them if they can coat the inside. This is commonly done with metal tanks and it seals pinhole leaks and stops corrosion. Find out if this can be done with the Ford plastic tanks. Products are available that claim to do this, though I don't know if any are professionally acceptable and effective.

https://caswellplating.com/epoxy-gas-tank-sealer.html

Also, before you go down this route, make darn sure the tank is leaking and don't just accept someone's word for it. I never heard of this happening, but I'm not a tank guy. It's much more likely the problem is in a hose, rotted steel line or elsewhere.

It's not easy, but I'd pressurize the tank and check for leaks or have a place that specializes in tank repairs do that.

-- One more joy of owning a 22 year old truck.

Has the right head gasket started to leak oil above the starter yet?
 
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Don Hall

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Research eBay:
eBay item number:
274512516985

Fuel Tank Fits 99-02 EXPEDITION 9806923

Condition:
Used

Price:
US $75.41
 
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Robert Wagner

Robert Wagner

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If you have a local rebuilder of tanks, you may ask them if they can coat the inside. This is commonly done with metal tanks and it seals pinhole leaks and stops corrosion. Find out if this can be done with the Ford plastic tanks. Products are available that claim to do this, though I don't know if any are professionally acceptable and effective.

https://caswellplating.com/epoxy-gas-tank-sealer.html

Also, before you go down this route, make darn sure the tank is leaking and don't just accept someone's word for it. I never heard of this happening, but I'm not a tank guy. It's much more likely the problem is in a hose, rotted steel line or elsewhere.

It's not easy, but I'd pressurize the tank and check for leaks or have a place that specializes in tank repairs do that.

-- One more joy of owning a 22 year old truck.

Has the right head gasket started to leak oil above the starter yet?

The shop that diagnosed the issue performed a smoke test and took photos of the smoke emerging from leaks of the tank. So I have high confidence that my tank is compromised.

It may come down to using epoxy, in some shape or form, as "stop gap" as there doesn't seem to be a lot of options (so far).

With respect to the right head gasket leak issue, there hasn't been a documented sighting by my shop on that particular area (they are very thorough... for example they did note during the tank diagnostic that there is a oil leak next to the oil filter mount).
 
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Robert Wagner

Robert Wagner

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Research eBay:
eBay item number:
274512516985

Fuel Tank Fits 99-02 EXPEDITION 9806923

Condition:
Used

Price:
US $75.41
Thanks for the reference, but it is my understanding that the 2WD and the 4WD tanks are different and the aforementioned auction is for a 4WD.
 

Hamfisted

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Looks like either the vent valve grommet is dried out and leaking air, or the vent valve is possibly cracked and leaking air. Either can be repaired / replaced with available Dorman parts if you can't get it from your Ford dealer.

Or there are many available sealants and epoxies that would do the job as well. Some shops won't do sealants and / or epoxies because of liability issues. But if you can do the work yourself, use what you want.
 
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Robert Wagner

Robert Wagner

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Looks like either the vent valve grommet is dried out and leaking air, or the vent valve is possibly cracked and leaking air. Either can be repaired / replaced with available Dorman parts if you can't get it from your Ford dealer.
Intriguing idea.

The issue is see is that I am under the impression, and please correct me if I am wrong, that the black circular "nipple" that the smoke is pouring out of is "welded" onto the tank. I seem to recall reading that the part is sonically welded to the tank during the manufacturing process.

Not owning a sonic welder, nor skilled in sonic welding, I don't know how I would replace the defective one with the new part if I hand my hands on one!

Maybe if I tighten my thinking cap.... the answer will be revealed...
 

Jay Federici

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Can't tell from pic exactly where the leak(s) are located. If it's the hard plastic that's cracked, how about cleaning and applying some epoxy to seal it from the outside? Just a thought but then again the ethanol/fumes may not be friendly to the repair. Is there an epoxy mix that can hold-up to the gas and fumes?
 
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JamaicaJoe

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I am curios as to how you became aware of the leak? Smell of fumes? A failure code? I have a 2001 and smell fuel when I exit the vehicle. A new gas cap seemed to help, but it is back.

Sent from my SM-T350 using Tapatalk
 

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