2003 Fuel tank, EVAP assembly, power drivers side seat track…

[sboychuck]

I am the original owner of this California Emissions SUV, with 145K miles, 4WD. It keeps sensing the vapor leak and setting a check engine light.

The molded plastic EVAP fitting(s) on top of the tank have hairline cracks, that are no longer sealing with JB Weld. So, I am searching for a new old stock fuel tank, or a good used one. It would also be great to also get the EVAP hoses and charcoal canister, in case that is also needed. Does anyone have any thoughts on a good source? I am in SoCal and can drive fairly locally, or having it shipped would be fine as well. The Ford fuel tank part number is 2L1Z-9002-AK.

The power drivers seal track also has some slop in it, about 0.25”, unless it is all the way forward or backward. So, I am looking for a track assembly. I had both front seats reupholstered a few years ago, so I just need the mechanical parts underneath, but would take the whole seat and frame.

Again, if anyone has some leads, I would appreciate the help. My internet search is failing me.

Thanks in advance…

 

[whtbronco]

You're likely stuck with salvage yards for the seat track and fuel tank. I have looked at several used fuel tanks and each one has the seams splitting on the vent ports. Maybe find a place that can plastic weld it. Most body shops are familiar with plastic welding and might be willing to weld the seams if you clean and dry the inside of the tank yourself.

I spent years looking for a manual seat base for the driver seat in my 2004. I finally gave up looking, but I still despise power seats. Every single one I found in a salvage yard had a power driver seat.

 

[SafariGoneWrong]

To stop the driver's power seat back and forth rock, I found this some years ago on the F-150 forum and it worked for me. "I basically disconnected the drive motor, then I "preloaded" the tracks slightly by adjusting one side forward and then reconnecting the drive." It makes the motor labor somewhat, and certainly not a permanent solution, but the way I looked at it nobody drives the XLT but me so the seat stays in one spot and the motor almost never gets used. At least it doesn't rock back and forth any more. Give me a manual seat track any day. And cables going from the HVAC mode door and blend door to the dash controller.

 

[whtbronco]

To stop the driver's power seat back and forth rock, I found this some years ago on the F-150 forum and it worked for me. "I basically disconnected the drive motor, then I "preloaded" the tracks slightly by adjusting one side forward and then reconnecting the drive." It makes the motor labor somewhat, and certainly not a permanent solution, but the way I looked at it nobody drives the XLT but me so the seat stays in one spot and the motor almost never gets used. At least it doesn't rock back and forth any more. Give me a manual seat track any day. And cables going from the HVAC mode door and blend door to the dash controller.

Hmm, interesting idea to help with the rocking motion. We move the seat all the time so maybe a good option for me. I get so tired of waiting for power seats to move. On our Monte Carlo's it's painful to bend over and wait for that dang seat, sometimes I just kneel down.

Yes, yet another thing I miss about my 78 and 79 Bronco's is the simple cable operated HVAC.

 

[BlwnAway]

As @whtbronco suggested, look into plastic welding your existing fittings.
If you can't find a shop to do it, get something to experiment with and try it yourself.
It's easier than you think.
This kit works surprisingly well :

https://www.harborfreight.com/80-watt-iron-plastic-welding-kit-60662.html

Esp, the flat rods.

Just make sure (if you do it yourself) you grind out/off all the JB Weld and create a small bevel in the crack to fill (Dremel for grinding and shaping), just as you would with metal welding. Plus clean with acetone before melting in the new plastic.

Since I've started plastic welding, JB Weld is only "very" temporary for me.

 

[engineer1]

Good advice from BlwnAway to COMPLETELY eliminate any trace of epoxy before welding. Be sure to use HDPE rod (high density polyethylene). I successfully welded my '03 tank a few years ago. The info with photos is in this link. Good luck. https://www.expeditionforum.com/threads/need-to-replace-my-fuel-tank.47332/page-2

 

[Speed 330]

To stop the driver's power seat back and forth rock, I found this some years ago on the F-150 forum and it worked for me. "I basically disconnected the drive motor, then I "preloaded" the tracks slightly by adjusting one side forward and then reconnecting the drive." It makes the motor labor somewhat, and certainly not a permanent solution, but the way I looked at it nobody drives the XLT but me so the seat stays in one spot and the motor almost never gets used. At least it doesn't rock back and forth any more. Give me a manual seat track any day. And cables going from the HVAC mode door and blend door to the dash controller.

Take the seat tracks apart go inside and change the bushings will solve all that

 

[sboychuck]

So, I was able to find a 2004 in a local scrap yard. It had a good fuel tank and power drivers side front seat. The fuel tank came with all the EVAP hoses and charcoal canister as well. They are going in right now, and I will be back on the road soon. Thanks for the help all…