Leaky gas tank

[DarkPhoenix]

Okay, I changed the filler pipe on my BG, only to have the tank leak when I fill it up. Now, I did notice the vent pipe is corroded as well. I am ordering the part from the dealership so I can replace it. I looked to see where the leak was coming from up top. I can't tell if it is a bad hose, clamp, or just corrosion on the tank. Do Subaru tanks just rust out like that? Or could it be that I just fucked something up changing the filler pipe neck.

This car is giving me more and more agita everyday.

[chuckthefuk]

I feel your aggravation..

This morning I woke up to a pot hole size gas dent in my driveway.. EPIC FAIL.....

So I will also be changing out my filler neck.

Please post pictures of your repair it will help move this thread towards a solution..

From the fleet of aged Subaru's I interact with no one has ever had a rusted gas tank and this includes cars so rusted that the rockers are missing. But that being said rust can eat away at the tank but I wouldn't say its common.

-Chuck

[DarkPhoenix]

^^ Will do chuck!

[prodriver1]

let me know if you need any more parts. I have the tank still if you need.

[httrdd]

How do you guy know that you have a leaking tank? Is there physically a puddle under the tank? I am having a fuel smell coming from the rear of the car, but no leakage. My buddy told me when you fill the tank to the top and overflow (adding too much) you have a canister that fills with gas and overtime you will start smelling it. Not sure about this one, but it is definately coming from the vent.

[chuckthefuk]

Like I said in my first post.. I have a "pot hole size gas dent in my driveway" meaning gas dripped on to the driveway and ate right through the asphalt. So yes there was a puddle..

I have only once over filled my tank and trust me gas will poor right out of the vent tube if I recall correctly.

Your evap system does vent through the charcol canister located next rear right of the car. Its possible that one or a few of the evap lines are broken, ripped, leaking and that may be the gas you smell.

-Chuck

[httrdd]

Yea I figured something might be wrong. How do I go about replacing the parts? Pretty easy?

[DarkPhoenix]

Yeah, I have a puddle on the right side of the car whenever I put in more than 10 gallons of gas. After looking at it, it looks like it is coming from the same area that the rubber hose from the filler pipe mates to the gas tank. I'll me taking the rear out to reseal it, and at that time I will be dropping the tank to see what is going on. I think it is just the rubber hose itself, so if you got any of those, Pro, let me know.

I will post up pics once I get the chance.

[prodriver1]

Yeah, I have a puddle on the right side of the car whenever I put in more than 10 gallons of gas. After looking at it, it looks like it is coming from the same area that the rubber hose from the filler pipe mates to the gas tank. I'll me taking the rear out to reseal it, and at that time I will be dropping the tank to see what is going on. I think it is just the rubber hose itself, so if you got any of those, Pro, let me know.

I will post up pics once I get the chance.
Ya I'll check if I have it still, if I do I'll just send it out. hopefully your tank isn't getting porous. if so I do have the tank still from the cally car.

[DarkPhoenix]

Yeah, I have a puddle on the right side of the car whenever I put in more than 10 gallons of gas. After looking at it, it looks like it is coming from the same area that the rubber hose from the filler pipe mates to the gas tank. I'll me taking the rear out to reseal it, and at that time I will be dropping the tank to see what is going on. I think it is just the rubber hose itself, so if you got any of those, Pro, let me know.

I will post up pics once I get the chance.
Ya I'll check if I have it still, if I do I'll just send it out. hopefully your tank isn't getting porous. if so I do have the tank still from the cally car.

Thanks bro. The tank is gonna be expensive to ship due to the size of it. I may have found one local though, but I don't think it is the tank. Only time will tell.

[prodriver1]

Yeah, I have a puddle on the right side of the car whenever I put in more than 10 gallons of gas. After looking at it, it looks like it is coming from the same area that the rubber hose from the filler pipe mates to the gas tank. I'll me taking the rear out to reseal it, and at that time I will be dropping the tank to see what is going on. I think it is just the rubber hose itself, so if you got any of those, Pro, let me know.

I will post up pics once I get the chance.
Ya I'll check if I have it still, if I do I'll just send it out. hopefully your tank isn't getting porous. if so I do have the tank still from the cally car.

Thanks bro. The tank is gonna be expensive to ship due to the size of it. I may have found one local though, but I don't think it is the tank. Only time will tell.

word son :smt023 PM me your address again and I'll let you know how much shipping was after I send it. be like $5-$10 I should think.

[nikolaus.conrad]

I found this thread and I was wondering if someone might be able to help me out a bit. The tank leaks on my 1996 Outback 2.5, much worse than Chuck's and Phoenix's. Mine won't hold more than 1/4 of a tank without dripping and strong fumes. I have a donor car and I'm wondering if there might be a thread or a site that shows how to remove a fuel tank? Thank you!

[chuckthefuk]

Are you sure its the fuel tank itself?

All Subaru Factory Service Manuals show you how to install and uninstall every component.

You can find them located in the Literature / Manuals section.

-Chuck

[NGTD]

Look on-line there are FSM copies that are available. I found on - basically you have to remove the rear diff and the entire subframe to change the tank.

Mine was leaking from the left side fuel level sender. the tube coming out was cracked.

[nikolaus.conrad]

Chuck- I'm not 100% positive because I can't see up there to know where it's coming from, the previous owner said it was the tank, I know these Legacys are famous for the fuel necks rusting out on top of the tank so that might be it also. I have a Haynes like manual and I'll double check for the steps there.


basically you have to remove the rear diff and the entire subframe to change the tank.

I had a feeling that was coming, I hope mine is as easy as a fix as yours, at least that's how you're making it sound :P

Thank you =]

[ouch1011]

My buddy told me when you fill the tank to the top and overflow (adding too much) you have a canister that fills with gas and overtime you will start smelling it. Not sure about this one, but it is definately coming from the vent.

That is one of many reasons why "topping off" the tank after the pump shuts off is now illegal (at least it is on Oregon). It'll either spill on the ground (environmental hazard) or flood the EVAP system and ruin it.

[chuckthefuk]

For anyone who wanted to know heres a DIY

viewtopic.php?f=39&t=23060 (https://sl-i.net/FORUM/viewtopic.php?f=39&t=23060)

[nikolaus.conrad]

You are amazing Chuck!!

[dimwittedmoose51]

I'm getting in on the thread about 4 years late, but I am in the process of replacing my tank on my 96 Brighton Wagon.

One thing to check on is remove the plastic rock shield that protects the filler pipe from road grunge and see if the pipe has accumulated enough salt etc to rust through in that area. A lot easier to replace/repair than dong the tank. That shield actually does mre harm than good trapping salt in there so the corrosion continues longafte the xposure. Mine wasn't rusted, but my tank was rusted through at the inlet nipple and although the gas cleakage is worse in the summer(can only put i like 6 gallons before I have "issues", but winteer isa little more forgiving.

If nay of you choose to replace the tank, make sure the donor ar you get the tank from has an intact rear hydraulic brake line you can also harvest. If the tank is ruaty that far up, your brake lines are near toast as well. It would be a grand idea to do both jobs at the same time.

I harvested a nice but not perfect tank from a junk yard for $35 and they left the pump and left side sender with the tank(score). The tank needs just a little touch up on some surface rust to be totally healthy. The brake line from its neighbor in the yard was immaculate and the guy pulled it and sold it to me for $15(another BIG score).

I can keep everyone appraised of the progress as it continues, but right now we're getting the wheel bearings pressed out and new ones in. The right rear lateral plastic bearing cage was cracked and the balsy rumble was unbearable inside the car. Really hard to tell where the noise was coming from too.


Out

DM&FS