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Dassquatch 07-13-2013 12:29 PM

Not becoming a fireball.
1993 Jeep Wrangler S.

Alright.... I have developed a leak on the top of my tank. It only seems to leak when I'm driving somewhere. I had it idling with the tank down today and after about 5 minutes, there was no leak or gas smell. I dropped the tank today and...... No cracked hoses or other easily visible sources.

Here is what I saw:

1 - The leak seemed to be coming from the tilt-over valves on the top of the tank. This would explain the short spurt of gas that happened the other day when I filled it up.
2 - The return line had become mashed a bit against the body.

Mods that may have contributed to the leak:
1 - 15-20 gallon mod. The gas sloshing against the tilt-over valves may have worn them the rest of the way out. She is 20 this year.
2 - I put a brass junction in the out line to compensate for the lack of a 3/8-5/16 hose when I originally pulled her out of storage. I would like to note that there was no cracking or other deformation on the out line.

Anyone out there got ideas?

I would like to know if anyone else has had this problem. Or something similar. Thanks for your time.

dukes-o-hazard 07-14-2013 03:36 AM

How much hose did you cut off/back when you performed the 20 gal. mod? When I did the mod on my jeep over a decade ago I could still only fit 19 gallons before the pump would click off. Still no complaints for a free simple mod that gave me 4 extra gal. capacity for free.

Dassquatch 07-15-2013 11:48 AM

I can get about 16-18 gallons in from near-empty. It was actually the hose at the hard line just ahead of the frame rail that had come loose because the return hose was pinched. Lame.

dukes-o-hazard 07-15-2013 09:03 PM

Doh! Well sounds like you got some fuel tank removal practice in anyways! :facepalm:

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