Gas Tank Question

[nikolaus.conrad]

Hello all! I'm currently looking at a 1996 Legacy Outback automatic :-( for a new car, the only problem is, it has a leak in the gas tank. I have a Legacy sedan 5 speed which I will more than likely use for parts, it has a tank in better condition and I'm wondering if it will swap out or not?

Thank you!

[phi11]

are you sure it's the tank?
most of the time it's the filler tube.

[nikolaus.conrad]

The owner says it's the tank, but whether it's the tank itself or the neck I have no idea. I'm just trying to picture a worst case scenario that if I had to swap tanks, would they be interchangeable?

[Huffer]

Tank should swap, but the likely culprit for leaking is the filler neck.

[phi11]

you didn't tell us what the " Legacy sedan 5 speed " is.

if it's fwd, the tanks will be different.

[nikolaus.conrad]

The 5 speed Legacy is AWD

[czsmola]

if both are are AWD then should work personally I have a tank out of an impreza in mine. only difference was there was an extra vent line that I T-ed into the filler neck vent but now I have to un hook it so I can fill the car. It is kind of a pain in the ass but it gets the job done..

When I did this job the biggest thing a learned is that it is best to jack the car up high, and then drop the rear subframe along with the suspension. you need TON's of clearance.

[silver_s13]

I have a question that kind of goes along with this question. Is there a larger capacity tank that will fit in a BG? Maybe from a leter model legacy? Rolling with 12 gallons @ 23 mpg doesnt cut it for me.

[Dead91silvia]

All AWD tanks from 1995-1998 will fit.

Even some Impreza tanks interchange. If you need a fuel filler neck, I have one thats rust free...

[96LegacyWagon]

All AWD tanks from 1995-1998 will fit.

Even some Impreza tanks interchange. If you need a fuel filler neck, I have one thats rust free...

My 96 Legacy Wagon AWD leaks gas when I fill it up as well... possibly the filler too? How would I go about checking (and if needbe, replacing) that?

[chuckthefuk]

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

[nikolaus.conrad]

Dead- I may just take you up on that offer, PM me!

How hard of a job is to replace a gas tank at home? I'm just worried about snapping the bolts that hold the subframe in place if I did it myself.

Also, it is the tank that leaks, anytime I fill it more than 1/4 it leaks on the side facing the front of the car. more than 1/2 tank it drips in multiple places on the front side.

[Dead91silvia]

Yeah, let me know..

Changing the tank will be a big job for sure. If I remember right, you dont need to drop the complete sub frame, just the front half. Another thing to look at also is all the lines for the pump and cross over pump. There are two access plates, just pull them and take a look.

[chuckthefuk]

dead's bang on.

Easiest way to do this is to take the subframe and all accessories with it.

-unbolt struts from the bottom (leave bolted at the strut tower)
-unbolt fuel filler tube
-disconnect brakelines
-disconnect e-brake (easier to removed from the handle and then pull it out of the frame so it goes with the subframe)
-disconnect driveshaft (you will need to refill transmission fluid after re-installation)
-unbolt trailing arms (control arm from hub to under the rear door)
-unbolt the subframe

You end result is this

https://sl-i.net/FORUM/images/imported/2009/10/4676073330_00683b85ec_b-1.jpg

As far as the tank goes
- disconnect all hoses/connectors form the 2x access hatch.
--> passenger hatch = main sending unit
--> driver side hatch = secondary fuel leveler and jet pump
- unbolt gas tank straps
- lower tank.


RE-and-RE

-Chuck

[nikolaus.conrad]

Doesn't sound too diffucult to drop the rear subframe, I'm just worried about snapping the heads on the bolts that hold it in place. if I do this it'll be the same time I replace my transmission with a manual. Kill as many birds with one stone as possile lol. I think I can do this, I'll be sure to ask lots of questions if I come across any. Thank you so much Robin and Chuck! =]

[d1giPhux]

Hey, if your gonna do this.. be sure to take lots of pictures!

I especially want a view of how the brake lines run under the gas tank, it would be great for a thread i've been working on.

Definitely try to take lots of pics though!

[nikolaus.conrad]

I'll be sure to create a DIY Thread for this :smt023

[Dead91silvia]

Just make sure you got LOTS of WD40 or what ever you use for busting rusted nuts... I'm sure you can do this, with what I've seen of that Spitfire you have, this should not be a problem. :smt023