FEOA Forums banner
1 - 12 of 12 Posts

·
Registered
Joined
·
6 Posts
Discussion Starter · #1 ·
:sleepy3: Hey everyone! Let me start by saying that finding this site was the best thing that has happened to me since I started working on my girl's '97 2.0. The info I was able to find by searching the forums has saved me countless hours of aggravation and gallons of sweat (it's kind of muggy here in Hawaii this week). Just today I was able to quickly find the source of a low rough idle (it was a hole in the elbow where the PCV tube connects to the intake plenum - the rubber has turned to soft putty) due to some late-nite forum trawling last night.

Now on to our next problem... Everytime that the gas tank is filled above a half tank there are very strong fumes inside the car anytime the fuel gets sloshed around. With some info gleened from searching the forum last night I concluded that it was probably the o-ring on the fuel pump flange. When I disassembled it the o-ring did appear to be out of place and seemed to have some marks indicating gas getting by it. So, being that it was still in very good condition, I just cleaned it all up and lubed the seal with some silicon o-ring lube (had it in my dive gear bag) and put it all back together nice and tight. Well, as soon as I took it up to the 76 and filled the tank to full, I looked inside the car to check it out (I had left the back seat and cover off to be able to do a final inspection) and there was an obvious flow across the area of the top of the tank - smelled strong as hell and was still wet. It does not appear to have come from the flange itself, but from somewhere higher up on the tank towards the rear of the car. Unfortunately, I can't see very much through the access hole and the tank is now full of fuel - making dropping it even that much more of a pain.

This is where my question comes. It looks as if I will have to remove the exhaust from the cat back in order to drop the tank since all the shielding around the exhaust near the tank is attached to the tank scuff guard. Is there an easier way to get at the top of the tank? Suppose I just unbolt the back of the tank straps and drop it a little bit, will I be able to see the rubber that connects the fill and vent tubes to the tank through the access hole, or am I just going to have to bite the bullet and do it the obvious way?

Any of you guys ever drop the tank on this model? Is there anything else I should know to make this easier on myself?

Thanks again for all the great info on this site and hope to hear from some of you soon!

Aloha
Steven G. Riggs
a.k.a. bay0ub0y
 

·
Registered
Joined
·
1,204 Posts
well before you go messing with the tank. what are the chances it is coming from the filler hose. Especially where it connects to the tank. Give those a try.... if you can see them first.

Just be damn carefull around gas fumes. Especially with static etc. Wouldn't hurt to have a decent size fire ext rated for that stuff just to be safe. I spent about two days dropping my sisters s-10 tank and swapping out pumps....twice! You could just see the fumes in the air... then again it was 118 outside!
 

·
Registered
Joined
·
6 Posts
Discussion Starter · #3 ·
The filler hose or the vent that runs along-side it are what I suspect. I can't, however, see the place where they enter the tank without dropping it at least some. I'm hoping that I can avoid removing the exhaust and all that shielding but it looks inevitable.

As for the fumes, there's not much chance of a static discharge here in Hawaii (I don't think a balloon and a pair of wool socks would even help on most days - something about being surrounded by water for thousands of miles) but that is a great suggestion about the fire extinguisher. I will certainly keep mine nearby. :violent3:

I'm about to get started now, but if anyone else has any tips please post them as I will be checking back throughout the day and someone else may be able to use the info, too!

Aloha!
bay0ub0y
 

·
Registered
Joined
·
6 Posts
Discussion Starter · #4 ·
Well, the tank's out...



and it appears to be a defect in the bonding around one of the vent ports...



To get this sumbitch out I did have to drop the exhaust (breaking only one bolt, suprisingly) but I still could not get the muffler loose from the exhaust pipe, so it is just hanging under the car for now. Good enough, though! It would have been much easier if I had a lift and some pneumatic tools - I would have just dropped the whole rear crossmember and it all would have come right out. That's how most of those brilliant designers and engineers build these things - dealer friendly, but not for your average driveway mechanic. :evil:

Anyway, do any of you know what would be a good sealant to use around this port? I've got some professional grade urethane for mounting windshields, but I'm not entirely sure that it will hold up to the gasoline for long periods of time. It's too bad I don't have one of those Spin-Welder toys that I had when I was a kid. That would work perfectly with the right plastic tips! Any of you remember those things? I've looked high and low and can find no reference to them anywhere.

I'll probably also Dremel out a groove around it first to get plenty of contact area. My main concern is getting a sealant that I know I can count on to go the distance. I definitely don't want to have to do this again! :pale:

Well, I'll post again after I get it all buttoned-up and let y'all know how it went.

Peace out!
bay0ub0y
 

·
Registered
Joined
·
6 Posts
Discussion Starter · #7 ·
There was a recall on the '95 Escort for cracks in the plastic fuel tanks, but nothing on the '97. I've looked at the TSB's for this car and seen nothing about the fuel tank.

Ultimately, I believe that I could talk to the dealerships around here until I was blue in the face and would get nothing but frustration. I've never once in my life that I can remember had a good experience with a dealership or the manufacturers. I cannot afford a lawyer and even if I could I don't think it would be worth it in the end considering the time involved and the pain of trying to share one vehicle with my woman for the next who-knows-how-long.

Good suggestion, though - it was worth looking to see if there was a recall - but that's all the time I'm going to spend trying to get Ford to fix their faulty tank. Hell, yesterday when I went to Honolulu Ford to get that PCV elbow they told me Ford only offered the whole assembly with the PCV valve and the long tube for $40! Screw that! I told the parts man that even if I did have that much cash on me I still would not buy all that as a matter of principle. I ended up with a molded 90 degree heater hose from Checker Auto Parts for $6 and fixed that, no problem.

But I digress. Thanks for the suggestions, I've got to get back to work before the sun goes down here in Honolulu. :D

Aloha!
bay0ub0y
 

·
Registered
Joined
·
6 Posts
Discussion Starter · #8 ·
Latest update: I believe we have a leak-free tank. Yay!!! Thank you, thank you very much. [/Elvis voice]

Here's what I did: I was pondering the best sealant/adhesive to use and thinking about that spin-welder when it dawned on me that this is just plastic - I have a plastic tip for my soldering gun (which also happens to have a low-heat setting for plastic) - there's plenty of material piled up around there - why don't I just weld that puppy together like it should have been in the first place?

Ta-dah!...



This is how we... this is how we do it... this is how we do it to it...



And the finished product...



The main thing I had to watch out for was air bubbles - and making sure I still had enough blood left in my body as the mosquitoes get quite hungry around this time of day. It seemed to go without a hitch.

Now comes the fun part of putting it all back together in the dark while being on my back under the car getting slaughtered by those #@$%&*@ mosquitoes. Then it's off to work in Waikiki all night. Yippee! But it will all be worthwhile as long as my lady can drive with a full tank of gas and not worry about blowing up if someone lights up a smoke around her. :blob6:

Aloha!
bay0ub0y
 

·
Registered
Joined
·
6 Posts
Discussion Starter · #10 ·
Ha-ha! Yeah, I guess it could be a lot worse. Amazingly enough, I didn't even get rained on the last couple of days while doing all this. That's incredible for this time of year back in our little valley. Normally, we can expect it to rain at least a couple of time per day, but I guess the gods wanted me to get this little 'scort back on the road.

The funniest part of it all is that even though her car is now in better shape than it has been in years, when I got up today my girlfriend had taken my car again! It's a convertible, so I guess I can't blame her. The weather has been pretty nice this week. Wait... this is Hawaii. The weather is always nice. But, you know what I mean, less rain and more sunshine than usual for this time of year. 8)

Well, everything went back together without a hitch and the only parts I had to purchase to fix the rough idle and the gas tank were a $6 hose and a couple of nuts and bolt to replace the broken one and its mate on the exhaust. Total cost of about $11 and a couple of days' labor... and some sore muscles from pushing around a full gas tank and fighting rusty bolts on the exhaust. A job well done and a major score on brownie points.

Next, I have to yank the radiator to fix a leak, but it's only a couple of drops here and there so that can wait until I get caught up at work. I'll definitely be checking back here for more info. Once again, thanks for a great site and all the great info!

Aloha,
Steven G. Riggs
bay0ub0y
 

·
Registered
Joined
·
826 Posts
I know this is a zombie thread, but I thought that I'd mention I dropped my 97s tank tonight (boy sure wish I'd read your tip on the exhaust...I just got pissed & mangled the heat shield to drop the tank...had to siphon it completely). Sure enough, as soon as I dropped it I saw the crack around the front vent, looks just like yours; it's a tad closer to the rubber, and a tad longer.
I don't have a plastic welder setup, but I'm just going to go pick up one of those plastic gas tank epoxy sets at the parts store. I think Permatex makes them.
Man I stink... :lol:
 

·
Registered
Joined
·
2,719 Posts
haha, I recently had to repair a couple hairline fractures in my gas tank (that's what I get for thinking my car is four wheel drive...). And we did it the same way you did. Just used a low powered soldering iron. But thankfully, didn't have to drop the exhaust in my '95...
 
1 - 12 of 12 Posts
Top