Gas Tank Replacement Questions

My CEL came on not too long ago and I found a P0456 code. Had the smoke test done and was told my gas tank flange is leaking air at the top. Oh boy, lucky me!

Dealer quoted me at $1130 for a new tank and straps plus about $20 for gas. I can also get $100 off that with a coupon I have.
A mechanically inclined friend said we can do the job together in his driveway to save some money. I've been browsing Toyota tank prices and finding they're in the $500 range plus I need straps.

Is replacing a tank a nightmare job that should be left to professionals?
Should I just do a Band-Aid fix and try and seal around the flange?

Here are some questions if I do decide to tackle this job with a friend.
Does anyone know the Toyota gas tank part number for a 2003 V6 access cab trd off road? I'm having trouble pinpointing the exact one.
Are aftermarket tanks a good fit or should I stick with OEM?

Any tips/suggestions from guys who've been down this road would be greatly appreciated.

I'm torn between spending the money and letting Toyota deal with it so I can be headache free OR saving some money by doing it myself on a cold driveway cursing the whole time. Decisions, decisions.

 

I don't understand what flange is leaking.

I had a Ford that had the filler neck leaking just above the gas tank. As I recall it screwed or bolted to a flange on the top of the tank and I replaced the whole filler neck for $80 and 45 minutes of work. I don't know if that is something similar to your current problem or not.

 

My tank is rusting out around the fuel sender unit on the top. There's corrosion all around it.

 

Ahh, yeah. My comment was of no help at all then. Sorry.

 

damn, I am looking to sell my spare gas tank, but I think you are too far from me to pick it up if you are interested (too big to be shipped) :/

Though, I did some gas tank repairs before, for friends or neighbors..... Do you have pictures of the problematic area of your tank? Did it rust through?

 

This is a tough call if this is a Long Island truck this could turn into a real project

Getting the fuel pump bracket out breaking the fuel lines loose can be interesting

I would want the fuel pump bracket and the fuel lines at least the pressure and return

Doing all this work could very well knock lots of dirt loose in the fuel lines good to have a fuel filter as well

I have changed a few over the years for sure I would think long and hard about doing it in the driveway after Thanksgiving in Ny

 

Not sure how bad the rust is. Bad enough to let air seep through and not hold a vacuum. I'll try to post a pic tomorrow. Busy day though so I might post it Saturday.

 

just weld it.....










jusssttttt kidding!

 

Thanks, Wyoming. I'm having similar thoughts like you. The risk might outweigh the reward. Part of me thinks I should just bite the bullet and let a shop take care of this.

 

Haha, sounds good! If I'm dead, all my problems go away.

 

My friend had his gas tank split right on the seam and spill half a tank of gas all over the gas station.
found a used gas tank and swapped it in an afternoon. just him and some basic tools.
It was a J.E.E.P though so take that for what its worth.

 

When the tank in my 91 4runner was rusted out I went to the auto dismantler and picked up a used tank in excellent condition for around 150 came with a fuel pump too. This was about 5 years ago.

 

Two of my tacos so far have had the flange gasket fail. Not a hard job at all. Run the truck till you are on empty. Unbolt the bed of the truck and lift it off. Six bolts hold the bed on. Tilt the front of the bed up and rest the rear on the back of the frame so you don't have to cut any wiring. take a few 2x4's and prop the front of the bed up so you can get to the fuel tank. clean off the top of the tank scraping any lose rusted metal off. lots of dirt and stuff up there. undo the two wiring clips going into the sending unit. there is i think 8 small phillips head screws holding the sending unit onto the top of the tank. unscrew them and you should be able to gently lift the unit out of the tank. you will see the problem. rust sticks to the rubber gasket and it loses a good seal. clean the rubber gasket real good and the flange of the tank and sending unit. then apply a small line of fuel safe sealant from carquest or napa all the way around the tank flange and set the rubber gasket onto it. then apply a small line on the rubber gasket and set the sending unit back onto the tank. bolt the sending unit back down and plug the connectors back in. then lower the front of your box back down, line up the bed so it sits correctly and bolt the four front bolts back in. I never put the two rear bolts in. seems like overkill to me and they are always a pain. the reason i say to run the truck till almost empty is so that if by chance you drop something into the tank while fixing it, it'll be easier to get it out.

 

I bought a tank from AZ for my wife's 98 4Runner a few months ago. It was $200 shipped to my door. Fuel pump bracket, gaskets, and screws was another $100 from a dealer online, 5 bolts and a few hose clamps, easy peasy. If you have a couple bolts break, like I did, no worries. They can be drilled and retapped once the tank is out. I would absolutely do this job in the driveway as opposed to giving a g note to a dealer

 

@cory02taco
"g note"

gonna use that in the near future.

 

Permission granted.
I stole it from someone way cooler than me anyways.

 

Thanks for the advice/tips.

Cory, do you remember where in Arizona you got the tank from?

 

It was listed on eBay, but I'll see if I can find the junkyard.

 

https://www.ebay.com/itm/302045377273

Would this work for you?

 

I just did this on mine, it was gravy. I do concur with removing the bed first, it makes it painless