E350 Gas Tank Questions

[Brit55]

Hi Guys:

I’ve just done a U-Joint 4” lift and 4x4 conversion on my 07 E350. The “expert” I had install the transfer case shortened the gas tank and MIG welded it despite my instructions to TIG weld it. Needless to say, it now leaks. I intend to take the tank somewhere else to get it fixed.
The Ford shop manual calls for special tools to disconnect the various hoses and makes removing the tank sound like a major operation. Is it really that complicated?
On a related note: I remember reading a post somewhere that talked about some sort of alteration to the filler hose to allow more gas to be put into the tank. Anyone done this without triggering an emissions fault?
Thanks in advance for your help.
Andy

 

[dsw4x4]

dropping the tank is not a big deal depends on the year if you need the special tool. All the tool is ac line disconnect tool can be had at the parts store for a few dollars.
The alteration I think you are talking about is on the oversized transfer flow tanks they can be modified to accept more gas.
You can probably get some tank sealant and slosh it around inside the side that was welded and it will seal it up. Most likely it is leaking where the two halves are seemed together it got to hot and melted the sealant back in the seam. If this is the case 15 bucks worth of sealant (it is like paint) sloshed around in the welded up side of the tank and allowed to cure will solve your problem for good.
Derek

 

[Brit55]

Hi Derek:

Thanks for the info. I may try the gas tank sealant as the leaks are more an annoyance than a hazard.

Andy

 

[ujoint]

The tank will have to come out anyway, so have the welds re done or add to them.

Or.... start over & have a new cap welded on. Let me know if you need another.

 

[BajaBus]

Mine was leaking as well from being chopped down. The jerks who fixed mine had it for 9 days, I got it back, filled it up and it was still leaking. Let's just say the guy got an earful when I stalked back into his shop 30 min later.

 

[Sheep Shagger]

I remember reading a post somewhere that talked about some sort of alteration to the filler hose to allow more gas to be put into the tank. Anyone done this without triggering an emissions fault?

I've only read / seen this on diesels, not gas.
You shorten the filler and breather hoses inside the tank, this will allow you to fill the last ~5gal without the pump constantly shutting off. This is very common on the F series and Expedition as they use plastic tanks and hoses, so a simple pipe cutter is all that's needed. Reach inside the tank with cutter and snip the end. Search "Harpooning tank" for full details.
The E series has metal tanks, and metal piping (I think metal pipes), so the mod is not so common on these tanks as you have to get in there with a grinder or something that will cut metal. My tank is ~32gal but I can only get 25gal in it before the pump shuts off, it takes 20~30 mins to get the last ~5gals in there, and I just can't be bothered with that.
So, if you are pulling it apart again and having it welded, I'd personally to the harpooning mod at the same time.
This will not change / throw any emissions codes on a Diesel.

 

[Brit55]

Thanks for the replies guys. The filler/vent pipe thing sounds like what I read about, but I'm not sure about cutting the steel pipes and making lots of fine steel debris to be sucked into the fuel system......
Perhaps if the pipes are thin enough I could get away with using tin snips of some kind.
I'll think about it and get back to you.

Andy

 

[nely]

If you modify the fuel tank on a gasser van to accept your more gas above the levels for the evap system, your likely to suck it into the vans charcoal canister and destroy your canister, Id advise to not due this unless you like replacing $300 charcoal canisters.

I would get the leak fixed and call it done.

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