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.



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!



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.



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



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 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?



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?



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

[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 . 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) 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