Awful Never Ending Gas Tank Project

[brokedownboys]

Vans first anniversary coming up. Still have not gotten any use out of it.

The first problem we observed was a fuel supply issue. When I dropped the tank to replace the fuel pump I did not like the rust in there.

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Came up with an effective way of cleaning rust out of a tank. Filled the tank with rocks, plugged all the holes with rubber stops and added some water, then sloshed it all around. By strapping it all to this giant wooden spool, I was able to get most of the surfaces clean!

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I even added a layer of POR-15 gas tank sealant for good measure. But to be honest, Im not sure I would recommend POR-15 for this application. This tank has so many baffles and internal hoses that I didn't get 100% coverage...I could double down and do a second coat but im just not sure.

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Also, the POR-15 ruined the my Filler Neck Flap Door thing...how the tf do reach in there and replace it ?? :rol:

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Unfortunately I did all this work hastily because I didn't have a shop and it was winter in Montana. When I started it back up this summer I discovered a big gas leak coming from the tank :doh: So the tank is back out and I am re-inspecting my work....

This Fuel Pump O-Ring from Rock Auto always fit a little funny... could this be the source of my leak?

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I also found this random Toyota fuel level sender from eBay. It's almost a perfect fit...almost. As you can see, the bolt pattern didn't quite line up. Could this "modification" be the source of my leak?

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Thanks for the advice. Gotta get it right this time...so tired of dropping gas tanks. :redvan:

[timsrv]

I went through this a few months ago when I put a 4wd transmission into my 2wd van. My tank was actually worse than yours when I started. I used a mixture of vinegar and CLR (mostly vinegar), river rocks, and I put the tank into a cement mixer I rented from Home Depot :rol:. I can post a video of that if anybody is interested. I ran it for ~ 4 hours, then flipped the tank around and ran for another 4. It amazed me how clean and sparkly the tank was when I checked it. The little tube that goes into the fuel pump pick-up area had come loose and was rolling around with the river rocks, but I was able to secure it back in place with a long 00 welding tip and a long brazing rod. The brazing was a bit tedious but it came out nice.

Not sure about that o-ring, I like the original rubber seals. I always use the same ones over and over (never had one tear or fall apart). I also considered the tank coating, but decided against it due to the fill flapper and the little tubes inside.

[brokedownboys]

I will also testify to risk of damaging the internal parts via the rock tumbling method. I didn't break a hose, but I did dent the internal baffles. Worth it because the rocks clean well...just make sure you get a pressure washer to remove the residue left over from the abrasion.

After finally finding the correct OEM gaskets I reinstalled the tank and filled her up. I was so happy that I never have to mess with the gas tank again...until I ran out of gas with the needle on FULL!...Guess I got the polarity wrong on the little float bob sensor.

Oh well. At least the van is running and i'm not in immediate danger of catching on fire anymore.

[timsrv]

Good point about the rinsing. I have a spinning sewer jetter attachment for my pressure washer and I used that..........over and over again. After I thought I got it all I flushed a few times & dried the tank. After drying I banged it around and inspected with a light. I found a fresh pile of dust & grit in the low spot so I wrapped a small piece of rag with double back tape and attached it to the end of a coat hanger. That worked good for picking up the particles (applying more tape as necessary). I repeated that process a few more times until no new debris appeared. Since it was going to be a couple weeks before needed, after cleaning I put about a cup of wd 40 inside and rolled it around to keep it from rusting.

I also made the fuel filter mod (this post) (https://www.toyotavantech.com/forum/showthread.php?188-Fuel-gauge-not-working&p=13388#post13388) when I installed the tank & have been driving daily. So far I've put over 3,000 miles on it with zero issues (knock on wood). Tim