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03-09-2008, 11:29 AM   #1 (permalink)
finkster
 
Join Date: Apr 2002
Location: North SoCal
Posts: 424
Fuel leak!!!

I have a '96 F250, 7.5 liter 2WD, approx 190k on the odometer.
This truck has dual fuel tanks and yesterday I noticed there was fuel coming from the filler cap for the front tank. I unlocked the cap and the tank seemed to be pressurized. Fuel began rushing out of the tank and dumped what seemed like a quart of gas on the ground.
Is there a vent that could be clogged??
If not a vent, what else could it be? Could the warm day have contributed to this effect? As a side note, this truck has a week fuel pump in the front tank but would that be related?
How much of a chore is removing the front tank to get at that fuel pump??
Any help or direction is appreciated!

Thanx, Mike
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03-09-2008, 01:35 PM   #2 (permalink)
Blulakr
 
Join Date: Oct 2007
Location: Blue Lake, CA
Posts: 196
Re: Fuel leak!!!

There are check valves on the in-tank fuel pumps. If a check valve sticks open one pump sends fuel from one tank to the other. The tank that overfills likely has a bad check valve in the pump.

Replace the pump. Not a big deal. Drain most of the fuel first, loosen the filler neck then lower one end of the tank. You should be able to sneak the pump out.

I've also seen guys remove the bed of the truck to do this but I think dropping the tank is easier. Get a complete pump\sender assy, not just the pump motor.
______________________________________
'69 Coupe, 351C
'05 Super Crew 5.4L
'06 Fusion SEL V6 (momma's car)
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03-10-2008, 06:11 AM   #3 (permalink)
finkster
 
Join Date: Apr 2002
Location: North SoCal
Posts: 424
Re: Fuel leak!!!

Thanx for the reply!
I wasn't sure if those tanks could transfer fuel from one to another or not.
If I only fill and run off of the rear tank, am I doing any harm? I would think not but...?
I had Walbro send me a sample of the fuel pump unit but you suggest the whole sending unit/pump assembly, why?
Thanx for pointing me in the right direction!
Mike
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03-10-2008, 06:56 PM   #4 (permalink)
Blulakr
 
Join Date: Oct 2007
Location: Blue Lake, CA
Posts: 196
Re: Fuel leak!!!

"I had Walbro send me a sample of the fuel pump unit but you suggest the whole sending unit/pump assembly, why?"

You want to make sure and replace the check valve as well as the pump motor. I don't think the pump motor alone has a check valve.
______________________________________
'69 Coupe, 351C
'05 Super Crew 5.4L
'06 Fusion SEL V6 (momma's car)
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03-10-2008, 07:01 PM   #5 (permalink)
FEandGoingBroke
 
Join Date: Sep 2004
Posts: 12,101
Re: Fuel leak!!!

I don't think it can be the check valve in the fuel pump... They don't have check valves...

IIRC those are regular old Carter cigar shaped pumps...

Your problem is in the Switch Valve I'm betting... Which is foreward of both tanks a tiny bit, and quite a handfull to change Not hard, just a hassle...
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03-11-2008, 06:18 AM   #6 (permalink)
pedal2themetal45
 
Join Date: May 2002
Posts: 2,262
Re: Fuel leak!!!

Whats up with this I posted a reply here yesterday and saw it on here later yesterday and today its gone?? WTF
OOOOPPPSSSS i found it he posted this in the =Truck forem as well and thats were I posted SORRY
Tim
______________________________________
64 International 4dr. truck w/466

Last edited by pedal2themetal45 : 03-11-2008 at 06:25 AM.
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03-11-2008, 10:08 PM   #7 (permalink)
Blulakr
 
Join Date: Oct 2007
Location: Blue Lake, CA
Posts: 196
Re: Fuel leak!!!

Here's the text of a Ford recall for this condition. I realize now that it may not apply to your truck since the recall was for early 90's trucks but then again if you say your front fuel pump is bad why not replace it and see what happens?

NHTSA Campaign Number: 01I008000Manufacturer Campaign Number: Make: FORDModel: F250Year: 1990Component:
FUEL SYSTEM, GASOLINEManufacturers Involved: FORD MOTOR COMPANYBegin Date Of Manufacturing: 19890722End Date Of Manufacturing: 19930824Recall Type: IPotential Number Of Units Affected: 1556221Date Owner Notified By Manufacturer: 20010709Recall Initiator: ODIManufacturer Responsible For Recall: FORD MOTOR COMPANYDate Report Received By ODI: 20010719Date Added To File: 20010719Regulation Part Number: Federal Motor Vehicle Safety Standard Number: Defect Summary:
THIS IS NOT A SAFETY RECALL IN ACCORDANCE WITH THE SAFETY ACT. HOWEVER, IT IS DEEMED A SAFETY IMPROVEMENT CAMPAIGN BY THE AGENCY. VEHICLE DESCRIPTION: 1990-1993 FORD F-SERIES VEHICLES EQUIPPED WITH DUAL FUEL TANKS AND 4.9, 5.0,5.8, OR 7.5 LITER GASOLINE FUELED ENGINES. SOME VEHICLES CAN EXPERIENCE A CROSS TANK FUEL FLOW CONDITION DUE TO A DAMAGED CHECK VALVE IN THE FUEL PUMP/SENDER ASSEMBLY. FUEL MAY BE SUPPLIED FROM ONE TANK AND SOME OR ALL OF THE UNUSED FUEL MAY BE RETURNED TO THE OTHER TANK.Consequence Summary:
SHOULD THIS OCCUR, THE CAPACITY OF THE RECEIVING TANK MAY BE EXCEEDED AND FUEL MAY OVERFLOW FROM THE FILLER CAP.Corrective Action:
FORD IS EXTENDING THE WARRANTY FOR POTENTIAL FUEL CROSS-FLOW TO 12 YEARS OF SERVICE OR 150,000 MILES FROM THE VEHICLE'S WARRANTY START DATE, WHICHEVER OCCURS FIRST. THIS COVER WILL AUTOMATICALLY TRANSFER TO SUBSEQUENT OWNERS AT NO CHARGE. IF A VEHICLE ALREADY HAS MORE THAN 150,000 MILES, THIS OVERAGE WILL LAST UNTIL DECEMBER 31, 2001. IF THE VEHICLE IS EXPERIENCING A FUEL CROSS-FLOW CONDITION, DEALERS WILL REPAIR THE CONDITION FREE OF CHARGE.
______________________________________
'69 Coupe, 351C
'05 Super Crew 5.4L
'06 Fusion SEL V6 (momma's car)
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03-11-2008, 10:34 PM   #8 (permalink)
FEandGoingBroke
 
Join Date: Sep 2004
Posts: 12,101
Re: Fuel leak!!!

Good info!

Still, I never seen a check valve connecting two tanks at the fuel pump before...
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03-12-2008, 01:38 PM   #9 (permalink)
finkster
 
Join Date: Apr 2002
Location: North SoCal
Posts: 424
Re: Fuel leak!!!

The front pump is bad so it gets replaced anyway. I don't really want to spend the money on an assembly if I can just replace the pump module.
Thanx to everyone to chipped in here and on the Trucks forum, Mike
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