cracked fuel tank 2005

[RETROBIRD]

Going back to Ford on Monday. Service manager who took the car out for a test run after the tank was replaced had the a/c cranked up, so he knows it was working fine. Have no idea what could have possibly happened. They are going to test entire system. Will keep you posted

[RETROBIRD]

Pressure tested and put dye in, no leaks pressure ok, recharged system. They have NO idea why I lost Freon. This is why I stay away from dealerships unless absolutely necessary. I considered tank replacement necessary. Never again.....

[RETROBIRD]

Follow up on fuel tank....
turns out the tank is NOT cracked. There are two modules on the top of the tank that are NOT removable, even if they were I’m sure they would no longer be available. The actual problem is, one of those modules has somehow separated from the tank. The module is not loose in anyway but has a leak where it was heat sunk onto the tank. There is about an 1/8 of an inch ridge around the module and believe all I would need to do is put a bead of plastic around module. Have been looking into the process used and material needed. Has anybody else tried to repair these tanks. I talked with my service garage and they will perform a smoke test before I start process and again afterwards...

[Tbear]

Same thing happened to my 03 and they used the same procedure you are looking at to repair it. That happened several years ago and so far so good. No more issues

[BillyL]

This has been a reoccurring problem. I am told by a Ford engineer, the problem is not normally with the plastic tank, but with the filler neck support strength. They are designed to hold the weight of the gas pump nozzle only, not the added arm and body weight of the person fueling the car. I do not let the gas nozzle hang in the car fill port when fueling the car. I hold the weight of the gas hose off the car until finished. May be B/S but not problem yet!

[Fredrik73]

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.

HI Walter
is it possible that you can post photos of your broken tank from different angles and maby on the damage?
my tank is leaking too I can put gas just under half tank, above that it leaks out, I have not looked how much work it is to take down the tank but I have to do it this winter (this summer I repair my garage and hope it is finish soon so I can fix my Bird)
/Fredrik

[RETROBIRD]

Mine was not leaking fuel just vapor. It would not hold pressure causing the check engine light to come on. Had my service station perform a smoke test to determine where my leak might be. It was on top of the tanks around one of the permanently mounted modules. Removing the tank requires exhaust removal and drive shaft to be dropped. I can take pictures of old tank however it doesn’t really show any damage. Tried taking photo but won’t allow me to upload..to large. Not sure how to make smaller, pixels

[RETROBIRD]

I suggest you get the shop manual before attempting tank removal. I would also suggest that you begin looking for a replacement tank, just in case you might need it..

[Quickdraw]

Repair gas tanks yourself...

https://www.youtube.com/watch?v=dA7gQpHv9vs
https://www.youtube.com/watch?v=nf4USriwTJ0

[Fredrik73]

Thank you Walter
I will do it this winter, maby that's why I have the check engine light too.

[Fredrik73]

Repair gas tanks yourself...

https://www.youtube.com/watch?v=dA7gQpHv9vs
https://www.youtube.com/watch?v=nf4USriwTJ0

Nice links
I have bought plastic and carpet, hope that I can save the tank

[RETROBIRD]

Have a smoke test done on your tank. Need to be about 1/4 tank of fuel to test properly.

[Fredrik73]

Have a smoke test done on your tank. Need to be about 1/4 tank of fuel to test properly.

yes thank you
i will soon get my car back and then i must do something about the tank

[merlot4]

Mine just had the yellow engine light of death come on. Testing and a smoke test seem to indicate a faulty charcoal canister solenoid, so that is due to be replaced when the part comes in. I hope that's they got it right. Thanks to all for contributing to this thread, it never occurred to me that the gas tank could crack.

[RETROBIRD]

My light came on 3 different times. It came on showing my gas cap was bad. I replaced with Ford cap. Drove the car a few times, short distances, no problem. About a month later I went on a 30 mile trip and light came on again. That is when the test showed a major pressure issue. Hope you get lucky ...