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94' 3.0 Gas Tank leak


94' Ranger

Active Member
Joined
Jan 17, 2021
Messages
36
City
Southern California
Vehicle Year
1994
Engine
3.0 V6
Transmission
Manual
Tire Size
15in rims + Falken AT3
My 94' Ranger 3.0 looks like it has a gas tank leak coming from near the rear right corner. I found this ooze coming from the tank while trying to get my rear drum brakes working yesterday (following my lines looking for a hydraulic clog). I've gone from 17-19mpg to 12-13mpg over the last ~2 years so I'm kinda stoked to finally find the problem. A new tank would pay for itself in gas mileage in no time.

First question, from these photos, it looks like the fuel tank itself is what needs to be replaced, correct?
I cannot feel a crack, hole, or dent anywhere around the wet spot on my tank but it doesn't look like there's anywhere else liquid would be leaking from. I do a fair amount of off-roading, I'm thinking this might be a result of that. I read that it's fairly common that your fuel tank filler neck starts leaking in these 90's Rangers, but that's about a foot away from where I see my leak. From what I can see, the seam in the center of the tank is the main culprit for my leak.
The only "test" I've done is to put ~5-10PSI of air pressure into my tank to see if I could make it drip but that did not work.

From basic research, it looks like most people are pulling their beds off to more easily access the fuel tank and lines. Is that the best way to go about this if I'm replacing my whole tank? It's worth mentioning that I work at a shop where I have access to a lift if that makes things easier.

I was considering going to Pick-a-Part to see if I can find an old tank there but I'm leaning towards just spending the extra cash on a brand new tank ordered to the shop I work at. Worth it?


Not only is this causing awful gas mileage, it probably isn't very safe driving with gas drizzling down my tank, a random spark might turn it into a tinder box real quick.

As always, your advice, comments, and questions are much appreciated, thanks guys.

71234
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You can't get new tanks for these, just FYI

And wrecking yards often drill the bottom out to drain remaining fuel before they are put out in the yard, environmental thing
Or they are damaged by fork lifts used to move vehicles around

But sometimes you can get lucky and find a used one, try car-part.com

Regular cab has 17gal tank(16.5gal)
Extended cab or Long Bed has 20gal tank(19.5gal)

These are plastic tanks, and CAN BE REPAIRED using plastic welding
That's how they are made, the 2 halves are "welded" together, that's the line you see in the pictures

First I would ID the leak point
If possible have fuel level low, under 1/4 tank
Get a hose and damp towel/rag
Get a helper
Take off gas cap and put the hose in filler, wrap damp towel around the hose to SEAL the opening
Have the helper hold it and blow into the hose
Lungs can only generate maybe 2psi air pressure so you can't blow off any fittings
DO NOT use an air compressor for this or YOU WILL BLOW OFF FITTINGS

Listen for the air escaping at the hole in the tank
Air will be coming out in engine bay at the EVAP canister, that's normal

You may be able to fix the leak without removing the tank, it depends on where it is
There are many DIY articles/videos on doing this type of repair, using plastic welding and even JB weld type repairs
 
Last edited:
Find the leak first and foremost as these are a plastic tank and do not rot out like other tanks. Be sure it is the tank and not the sending unit or a line leaking.
 

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