Gas Tank replacement: Take the bed off or Drop the tank with bed on? DCLB

Hey guys,

I've got a slight leak in my gas tank as it got punctured on some highway debris, or while wheeling, not 100% sure. Wondering if anyone has experience dropping the tank on a 2nd gen Double Cab Long Bed, which I hear is different from the access cab and reg cab.

My Questions:
1. Will I need to take bed off? I've got my cap with Topperlift system as well as dual batteries wired in so taking the bed off would not be ideal. Plus I've heard of problems stripping the torx bolts due to corrosion, which is definitely a concern being a Rust Belt truck.

2. Should I replace my fuel pump while its off? Truck has 160K+ miles on it and I assume its an original pump.

3. Is it at all feasible to permanently patch this leak? I'm sure I could plastic weld it but would assume I would need to drop the tank and completely empty it before attempting something like that so I may as well replace if I need to drop the tank as tanks aren't all that expensive.

4. Any reason NOT to go with an aftermarket tank?

5. Any other words of wisdom?(beside get gas tank skids

 

How big of a leak? If you can get the gas level we’ll below the leak you can use a soldering iron to melt the hole back together. No it’s not hot enough to ignite fuel, ask me how I know.

Had the same problem, still have a new tank in the garage if it fails, but it’s been since June 2018

 

Too bad these are sold out...
I may or may not know who ordered the last two.

I have no idea on your tank removal, but I agree that you should get a skid!

 

My soldering iron runs at about 600F. Ignition point of gas is 450ish F. HDPE melts at 250-300ish F. May be willing to pick up a lower temp iron. Hole is on the bottom corner though. Stops leaking about when the E light comes on. Somewhere I have a wood burner. I believe it goes down to 200C(400F). Do I trust it. Theorhetically yes but, personally, no. I think I will end up dropping the gas tank.

 

No worries, I had trouble finding time and getting help with the bed. Maybe “not hot enough” was the wrong verbiage, more accurately there’s not a spark to ignite any fumes. Honestly, I was sketched the fuck out when I did it, read a lot of stories of people doing it and set the soldering iron low, but I was pretty nervous.

Mine was legitimately a damn pinhole tho and while I’d already bought a tank, it felt like such a waste to have something so small ruin the whole tank. Biggest point is that melting will reseal it, it’s not cross-link polymer or whatever afaik.

 

Im pretty sure the front end of the tank is under the cab so dropping it is the only choice.

I personally wouldn't mess around with a fuel leak, id replace the tank and also consider a new pump since its 12 yrs old

 

The proper way to weld HDPE is with a hot air welder. It looks like a giant pencil type soldering iron, except it blows hot air. I have used it welding a whole new bottom in a Banshee gas tank. Eventually it leaked and I had a custom aluminum tank built. Welding a very small hole might be succesful, but personally I wouldn't screw around. I would get a different tank.

 

Get a new tank/fuel pump reason #1 - You won't have to keep checking it forever. #2 - Chit fixes like this only lower the value of your truck, easy to spot on a pre-sale inspection. #3 - Speaks volumes about how you took care of your truck and will be worth more $ than it cost when you sell/trade, if you keep documentation proof.

 

I dropped my tank due to a pierced overfill line. It wasn't too bad, but the quick connectors were pretty frozen. Sprayed them with kroil. The easiest method was to drop the front first onto a bucket, then releasing the rear. All the hoses were pretty straight forward. Before reinstalling the tank remove both carrier straps and the job will be much easier.

I did all the work with the truck on the ground. The jack was used for repositioning

 

I thought all 2nd gen tanks were identical? Regardless of truck configuration.. Not 100% on that, just never heard anything to say otherwise

 

Maybe 35 years ago I had an ingenious idea to lift my little civic with a forklift. I caught the lip of the gas tank and put a pretty big leak in it. Fortunately I was in a fiberglass shop. I lifted the car so the hole was above the gas line with the same forklift. I cleaned up the tank to bare metal using brushes and acetone. I put on a few layers of resin and fiber glass. It held for years after with no issues.

 

The tanks are identical, but the long bed/short bed configuration changes access to the fuel pump when changing that. In this case, if you just need the tank outta there for a patch, I'm not sure it matters which way you go.

 

I wouldn't risk plastic welding the tank myself! Taking your time in accessing the tank from the bottom is far easier than taking the bed off. Starting at the filler neck and working your way down disconnecting either electrical lines, hoses, and clamps working your way out to the straps that hold the tank.

Some tools to look into buying before tackling this project you might consider getting would be, an impact screwdriver (You can beat the heck out of the impact screwdriver while beating a frozen or stuck bolt out without damaging the bolt). I got mine from Matco problem the best tool I've ever owned! Either aluminum or plastic fuel line disconnect tools most auto parts stores carry them. If your doing it on the ground a 4wheeler jack would help hold the tank but a normal car jack would be fine.

 

I would replace the tank or find a good used one at junk yard, would be cheaper. I would also replace the fuel pump while I have it off because it is not the most fun job to do so might as well while it is off. I have patched a few tanks in the past and some have held and some have not. But it is not worth the hassle to constantly have to check or worry if the tank is leaking again or not.

 

There was that guy on here who patched a pin hole in his tank with a short sheet metal screw and a small pilot hole..

 

Wood screw and j/b weld.

 

Thanks for the info. Will grab a fuel line disconnect tool. I have an electric mpact. Would never live without one. Really considering an air impact as well. Four wheeler jack is a great idea, thank you very much for that one. Question is, is it in the barn or at the cabin???

 

Too big for a screw. Its a crack. I puttied it temporarily and drilled out the crack tips to slow/stop crack propagation. A new tank seems to be my next step.

 

http://www.customtacos.com/tech.old...6toyrm/06toypdf/06rmsrc/rm2006ta/00900710.pdf
http://www.customtacos.com/tech.old.../06toyrm/06toypdf/06rmsrc/rm2006ta/009004.pdf
http://www.customtacos.com/tech.old.../06toyrm/06toypdf/06rmsrc/rm2006ta/009005.pdf

 

Flex seal