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I'm new to this site so please be gentle. Recently bought 2004 Vette. Has the leaking fuel tank issues. Has anyone had success with coating the tanks with a sealer as opposed to tank replacement?
I just went through this same thing. Just bought an '04, leaked at crossover tube connection on driver's tank when above 1/2 on the gauge. I bought a 40k mile 2013 tank with pump for $260 off eBay and did the swap on jack stands in my garage with standard tools in about 3 hours.
Edit: I used this thread as a guide for removal and reinstall. Any tank from 2003.5 - 2013 will work. If you use a tank from '07 (I think) or newer you will have to recalibrate the fuel level graphs with HPTuners or swap over your fuel pump assembly. I can give you the numbers I used for the recalibration if you go this route but you will still need access to HPTuners, the HPTuners MPVI 1 or 2, and $100 worth of HPTuners credits.
I have a question for you - does the tanks leak all the time or just when it’s filled to “full”?
leaks mostly when I fill the tank. Replaced the O rings in the crossover and helped somewhat. GM did an extended warranty for C-5s with this problem. The fix apparantly was to replace the tanks and hoses which would be very expensive as the extended warranty has expired. I've read that the tanks leaked at the top and was wondering if anyone had solved the problem with a tank sealer as opposed to replacing the fuel tanks. Thanking everyone in advance who can help. Rick
I work on aircraft for a living and when we have fuel tanks leaking, we have to seal them from the inside. If we seal it on the outside it won't hold for very long and will start leaking again. I'd say it won't seal properly and you'd wind up changing the tank anyway. So I'd just change it now and not worry about it anymore if it is the tank that's leaking and not something else.
I work on aircraft for a living and when we have fuel tanks leaking, we have to seal them from the inside. If we seal it on the outside it won't hold for very long and will start leaking again. I'd say it won't seal properly and you'd wind up changing the tank anyway. So I'd just change it now and not worry about it anymore if it is the tank that's leaking and not something else.
What a miserable job, eh? I wouldn't want to be crawling around inside a fuel tank. I've crawled around in some tight places in a KC135, but never had to go into a fuel tank.
What a miserable job, eh? I wouldn't want to be crawling around inside a fuel tank. I've crawled around in some tight places in a KC135, but never had to go into a fuel tank.
I was on deployment with SAC one time and got a ride in a KC-135. It was pretty cool to witness refueling B-52s as they are huge compared to a fighter. Got some awesome pictures too. I was TAC supporting SAC.
I was on deployment with SAC one time and got a ride in a KC-135. It was pretty cool to witness refueling B-52s as they are huge compared to a fighter. Got some awesome pictures too. I was TAC supporting SAC.
Never had that privilege but did get to ride on a C-130 at Nellis on a Red Flag deployment one time. Going through ravines so narrow the pilot had to put the plane a little sideways. Popped out of one ravine and back into another. Greatest roller coaster ride in the world!!!!
Yeah it was miserable. I was young, plyable, ignorant and only weighed about 140. When the work leads 1st saw me they immediately started smiling and said guess where you're going!!! My 1st 6 - 7 years in aviation was crawling around in a wing root of a 737 fixing leaks. Not every night mind you but a couple times a week at least. Nothing like getting all bruised up and smelling like fuel forever. Definetly can't be claustrophobic in there. Glad I work for someone that farms all that out now.
Getting off the track here. I have a '2000 with gas pouring out the right side of car after filling for the 1st click on nozzle. If 15gal or less it's OK. Tank is out rite now & found 2" crossover connector out of round slightly and tube clamp WAY over tightened. DEALER DID IT. Seam on tank bad on top by pressure test (2lbs!) Going to try plastic welding (has worked before on other low pressure tanks I have) for the seam and filler pipe for the crossover. Good luck finding a perfect used tank from a '00 to 03.5 and a 20 year old rubber tube is going to be useless. Keep you guys up to date.
I had this issue on my 2004 Z06/Z16 #165 but had it fixed under the recall/warranty GM did several years ago. The only insight I can provide is they found a way to do the fix with only removing the drivers side rear wheel and wheel liner. As I recall, earlier repairs had the shop removing the entire rear-end from the car. I waited until the local dealer had perfected the less invasive route. All is well with her now at 17 years old and 45K miles of smiles (she's a Dec 2003 build as an early Z16).
I also rode in a KC135 coming back from Korea to Okinawa one time...it sucked.
OP, If your referring to the gas leak from Cross Over leak my 04 had the "Cross Over" repair done and here are some pictures. Picture with finger pointing to white plastic part is the part that was bad. They were able to remove fuel system by removing driver side rear tire and plastic wheel liner.
Last edited by Borntorun04/17; Jul 8, 2020 at 08:15 PM.
I purchased complete tanks and crossover pipe from Vettepros. I think this is the best way to go. These tanks are outside the VIN numbers from the service bulletin. Now I have to find someone I can trust to install them. I'd do it myself but I'm old and disabled. I live near Ocala, Florida and a good honest mechanic is sometimes hard to find. Loved the pictures. Thanks.
Yeah it was miserable. I was young, plyable, ignorant and only weighed about 140. When the work leads 1st saw me they immediately started smiling and said guess where you're going!!! My 1st 6 - 7 years in aviation was crawling around in a wing root of a 737 fixing leaks. Not every night mind you but a couple times a week at least. Nothing like getting all bruised up and smelling like fuel forever. Definetly can't be claustrophobic in there. Glad I work for someone that farms all that out now.
Yeah, when I was in the A.F. it was JP4 that stunk up everything. At that time the only plane that used JP5 was AF1. And now EVERYTHING runs on JP8!
C5 gas tank issues
