cracked fuel tank 2005

[RETROBIRD]

I've been away from the forum for quite a few years for various reasons. Not sure how many bird owners out there have had engine light issues. I recently had my engine light come on and brought it to the shop to find out I needed a new tank cap. I purchased a new locking fuel cap from Ford and all was fine for about 2 weeks when I went on a longer than usual drive. There it was again, that annoying light. Brought her back to the shop only to find codes came up different. This time it was a major issue. Had service station do a smoke test only to find a major leak coming from the top of the tank. At this point I'm not very happy. Service told me it could be any number of things, none of which were going to be inexpensive. I decided I better bring her to the Ford dealership for this work. Ford confirmed the problem. I have my own repair manual for the car that my wife purchased for me years ago. I decided to look up what might be needed with repair work. To my amazement you can NOT buy a new fuel tank, in fact you can't find a used fuel tank. They have been out of production for years along with quite a few other parts. Ford had a recall on some 57 2005 birds due to defective tanks built in February of 2005. All these tanks were replaced prior to actual delivery. My car was built in May of 2005. It really doesn't matter Fords warranty on tanks was for 10 years or 100,000 miles. Turns out my tank has cracked on one of the two flanges where the fuel pumps are affixed. Dealership has found a tank and that alone will cost me about $700 bucks. When all is said and done probably around $1,500 I hope. This is basically an FYI to all owners. I have tried to cross reference other vehicles built on the same platform, like the Jaguar s/type and the Lincoln LS to find if any of there tanks would be a direct replacement, they all look identical. Maybe some of you tech guys would be a lot better at cross referencing these items. Not sure if there are people out there that can make new tanks. I plan on keeping my car until I'm no longer here..someone should look into this issue......and fast
Thanks for listening and happy T-Birding

[007Cruiser]

I think someone was trying to sell a tank here a few days ago. Is the tank not repairable?

[007Cruiser]

Found what I was referencing. There was one on eBay for $395 at the end of July. Must have sold, the sale is ended.

[RETROBIRD]

I had seen the same thing on e-bay. Was not sure my tank was cracked at that time. Was gone when I went back.

[Tbear]

I had the same thing happen to my WW. The Ford dealer fixed it with some kind of epoxy. No issues three years later.

[BillyL]

Ford dealerships are not into "fixing" parts, only replacing parts. Fortunately, I have not dealt with this problem on the bird yet. I did have a similar issue with a fiberglass tank in a boat a few years ago. A marine shop was successful in repairing the tank for me, did not seem to be a issue for them. You may want to talk with a independent shop about pulling the tank and repairing it first. Good luck and let us know the outcome. Thanks for coming back to the forum.

[007Cruiser]

Yes, marine shops do a lot of fiberglass repair. Billy beat me to he suggestion.

[RETROBIRD]

I requested my cracked tank back and intend on finding a repair person capable of this type of plastic welding. As I started earlier I had NO idea of the damage. Was told it could be a number of things so I decided to play it safe. After all who has the most Ford parts.

[BacktotheFuturePete]

Motorhome repair shops weld plastic tanks all the time.

[RETROBIRD]

Good to know ty

[RETROBIRD]

First replacement tank failed Fords smoke test yesterday. Second tank arrived today and going thru test. Sure hope the second ones a charm, there ain’t no third

[RETROBIRD]

Bird is back together and running fine. Second tank had no issues, passed all tests. Was blown away with what Ford charged. They had car for a week, checked out 2 tanks. Labor and parts and tax $841.
There is however a catch..... my air conditioner which I just had dye tested and recharged 2 months ago is now blowing HOT air. Have a call into Ford to see if they were in anyway responsible. Can’t for the life of me see how..

[BillyL]

Sorry you had to go though all that. I hope it has a good ending. I would ask for the tanks not used, both your original and the first one that failed the test since you paid for them. I think they are repairable and should be worth something to other members here. I still think they are repairable.

[RETROBIRD]

I only paid for the replacement tank that Ford used. I have my original tank in my garage and plan on having it repaired or attempted myself. I have found 2 sites that explain how they can be fixed. Fairly simple. Turns out my tank is not cracked. It seems that one of the 2 modules on top of the tank that are not removable has a leak at the joint where it attaches to tank. I believe I can run a bead of polypropylene around the entire fitting and that should seal it. Tank has barely any pressure in it when working properly.

[BLACK BEAUTY]

how's your A/C?