So I have a small rust spot (about the size of a quarter) thats bubbled up and weeping. I REALLY don't want to replace the whole tank as I did this on my wifes Civic last summer and it was a PITA let alone the cost of the tank, straps, filler neck, etc. (if Im tearing something big apart Im replacing EVERYTHING that goes with it so Im not working on it again). So anyway, I have a metal fuel tank and Im wondering if anyone has any sure-fire fixes without dropping it and doing the whole thing. Thanks!

 

If you need to remove rust or a lot of material to get a good adhesion surface, siphon the tank and fill it with water first. Then grind the spot or sand it. JB Weld works but AutoZone has a Permatex product called "gas tank repair."

 

Be prepared to chase this leak forever. You will NEED to replace the tank. It's not that bad as the XJ sits higher than the Civic. I was chasing my leak around for months using every wiz-bang "sealer" and goop out there. I ended up getting a nice used tank from the salvage yard for 40 bux, wire wheeling it and applying several coats of paint.

Just get as much gas out as you can. Removing the tank is not the end of the world. Putting the rear wheels on ramps gives you TONS of room to replace the tank. Hardest part I had was losing that little rubber thingy at the base of the fuel pump.

Im assuming you have a fuel pump in the tank? What year XJ are we working on??

 

Wouldn't suggest trying to repair a rust spot on your tank. I had a tube on the fuel pump come loose and was a bit of a nightmare(just filled tank and was out on a trail). Drove the time bomb home, drained tank and used JB Weld on it. Its been quite sometime now since repair, out on the trails, even a hard crash into a serious ditch, but still no leak!!! I did prep the area very well. I'm sold on JB Weld... But you can get the fuel tank, straps and filler hoses for like $130.00(new). Not so hard to replace and there would be no worries!

 

I'm not sure if the front mount pump ended with 94 or 95, (pressure went from 39 to 49 in 96), or if the top mount pump has them. Anyway, here is a pic of that secretive little bugger.


Below is the inside of the tank. The black ring you see is the end of the cone that belongs on the end of the fuel return line on the pump assembly. That cone on the metal line holds the bottom of the whole deal in place. That should be fished out, and installed on the metal fuel return line on the assembly. Then you seat the cone into the receptacle in the tank when installing it. The fuel return and pickup are located in a tray inside the tank, so return fuel is available to be picked up at the pump inlet, even when the tank is low or at an angle. This "tray" has a downside now with alcohol in the fuel. With just a little water, the ethanol separates from the fuel, it's heavier, and will be on the bottom. Without sloshing around, you could be recirculating a mess of alcohol and water right in that tray! Might run ****ie, might not.

 

cuda held a match there,git a little better light,,,

 

"Here, hold my beer and watch this!"

 

I just replaced the tank on my 1988 Pioneer, total cost was less than $200 for a new Tank/Pump/Straps. I suggest getting your hands on some jack stands or ramps, though, otherwise it's a serious PITA

 

No way would i even think about patching a rusted out fuel tank.

 

Just replace it, they are relatively inexpensive and not all that difficult to do on these cherokee's. You can get a tank for less than 100 bucks brand new. Tank straps are around 20.


Go check out RockAuto.

 

Agreed. Weld that sucker!



Kidding! I'm kidding! Don't weld a gas tank!






(Unless you actually know what you are doing...)

 

Pull a Macgyver and seal it with some chocolate.

 

Has anyone found an inexpensive replacement tank that has the mounting boss in the bottom? I bought a Spectra that didn't have it. Spectra and Dorman tech support both say its not included in their design.