Greetings,
I bought my sweet 2004C5 base Corvette w/ 25K miles on it. The gas gauge showed that the tank was about 1/4 full. Next day went out to take my car for a long spin and on the way home filled the gas tank completely full. Next morning I could smell gas in the garage and had some gas puddling under the tank on the floor. Long story short I discovered that the C5 Vettes had a recall several years ago for this very problem. It appears either the Gas tank(s) leak, or the crossover lines that siphon the two saddle gas tank together leaks or both. I couldn't find a new driver-side tank and had to settle for a used one from out of state. I had the used tank installed along with new OEM siphon lines and a new fuel pump too. I am not a mechanic and it cost me $4,000.00 for parts and labor. This just absolutely blew my mind. The transmission and exhaust pipes needed to be removed to do the work. Question: How many of my Form members had this happen to them? Can it happen to all years of C5 Vettes? Will it happen to me again? It is impossible to find new gas tanks for the C5's. Evidently GM does not make them anymore and I did not find a third party manufacture that made new one's either. Thanks for your replies in advance.

Edgemerski

 

From what I remember, the 2004's and the C6's had gas tank problems, C5's that are 2003 and earlier did not have this problem. Don't recall any other issues with the 2004 C5.

 

Sorry to hear about your bad luck. I bet the previous owner found out how much trouble and cost it would be to repair it and decided to sell it with a 1/4 tank of gas. Did you buy it from a dealer? If so, how long after buying it did you discover the problem? It's possible, although unlikely, that a dealer might offer a concession. If it was a private sale, you could go back to the seller and ask to split the cost. If it truly was a coincidence that it started leaking when you bought it, he might be willing to split the cost with you. Good luck.

 

Very sorry to hear about the leak in your '04. The gas tank recall involved late '03 and 04's with VIN numbers 45110258 to 45125500 to correct the cross over tank pipes leaking as a result of a batch of bad connecting compound. As I remember, the recall for those that leaked lasted for a specific time period and mileage.

 

I am adding to this post, related to all I have read about the 2004 C5 fuel tank leak. This is related to the defective issues and recall that I could not claim for repair. 10 years had and I was over 100k miles.

I had the dreaded fuel tank leak. The best I could see was the leak was coming from the crossover tube area, on the driver side. I could see fuel in the area using a bore scope video camera.
I did my research and then called around, and the repair estimate was CRAZY. I decided to look into fixing it myself.

I pulled the tank, without removing the drive system, which some repair facilities told me would have to be done. I got by with only having to remove the driver side rear exhaust and sliding the pipe out of the way. This also included the obvious, rear tire, tire liner, tank guard, vents and fuel connections, and pulling the driver side crossover tube from the tank without breaking the internal connector. At least 6 hours of work, most of which was one handed work, pulling the crossover tube, then the vent line connectors. I had to invent new tools from things I had in my garage to get it done.

After the tank was out, fuel stains were everywhere on the tank, and had no idea where the leak was coming from. To find the leak, I decided to seal up all ports on the tank and using a hand pump, I applied a small amount of pressure into the tank. Then sprayed soapy water everywhere. I found the only leak. The sealer that was used to attach the crossover receiver to the tank, developed a small crack. This sealer was the tank defect that I read was the problem and recall.

I thought I needed a new tank until I searched for one. They don't make 2004 C5 tanks anymore and the only ones available were used and could have the same problem. So, I decided to try and fix mine. I bought some 30-minute cure epoxy for plastic. Using a non-medical syringe made with a long tube, I cleaned the area using solvents to ensure the area was clear of dirt and fuel residue. Then, with my hand pump that also sucks air, I pulled a vacuum on the tank and injected solvent into the crack. Then after it was cleaned and dry, I pulled a vacuum on the tank again, and using the same syringe, I injected the mixed epoxy, as I watched it suck into the crack. Then added more around the area, building it up. After 24 hours, I pressure tested the tank again, with much more pressure, and the leak was repaired.

I have added this for future C5 and maybe C6 owners, with the same fuel leaking problem. You might get it fixed without paying 3K with only 90-day guarantee.
I have driven the car for about over 6 months and many miles, and there is no more fuel leaking.
Hope this helps someone out there.