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89 bronco leaking gas from the fuel tank

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#1 jlick


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Posted 07 September 2011 - 09:13 PM

Had my new bronco for about 2 weeks amd i just noticed it was leaking fuel from both sides of the fuel tank skid plate. I was just wondering if this was a common problem and where it might be leaking from. Im going to remove the fuel tank tomorrow. Can you tell me if there are any tricks or precautions i should take to doing this or if there is a common place that it leaks from. I already pb blasted the 8 skid plate nut and bolts. Any suggestions are greatly appreciated. And also the previous owner said he replaced BOTH? of the fuel pumps. There is only one place to put fuel in it. My last bronc was a 94 and i put a fuel pump in it and there was only one. Any help is appreciated. Thanks

#2 Rons beast

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Posted 08 September 2011 - 04:14 AM

Just have to take the tank down and examine it. It could be the hoses to the tank as well. Look for stains where the fuel is running from.

Dissconnect the battery to prevent sparks if you're removing the tank. and remember it can be heavy. I usually drive or drain the tank to just a couple of gallons.

I don't remember what years but some Broncs have a pump in the tank and another on the frame rail, with a resevore.

Good luck, keep us informed.

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#3 miesk5



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Posted 08 September 2011 - 04:25 AM

yo J,

Your 89 has two electric pumps; low pressure boost pump in fuel tank & a high pressure pump mounted on the driver's side frame

TANK Removal & Repairs in an 83 (he did an EFI Swap) Source: by Steve83

Some tips;

Remove batty neg cable
have fire ext and assistant
use brass punch or drift on tanks's 2" Lock Ring
Clean Before opening the tank, buy a NEW O-ring and wash any dirt away from the pump plate.
Posted Image by Steve83
Hard to Re-Fuel, Gas Station Pump Shuts-Off; "...There is a plastic vent tube inside the filler neck that often gets kinked..." Posted Image
Source: by justshootme84 (Randy Z, Casual Mudder) at Ford Bronco Zone Forums
V REST Vapor Valve (Roll-Over) Valve on later year Depictions & Location Diagrams in 5.0, 5.8, 7.5, & 4.9;

Get new straps & insulators too;
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# 30260
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OEM Valve

Price: $45.00
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#4 Seabronc


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Posted 08 September 2011 - 07:01 AM

When removing the bolts that hold the tank in place, be sure to support the tank so it doesn't fall to the ground. If you have a roll around shop jack it will probably be your best bet. Put a short board between it and the tank. After the electrical connectors, tank straps and hose are removed slowly lower the tank while you steady it with your hand. Just to be safe and to protect yourself, an ABC fire extinguisher, wear some protective nonflammable gloves (leather welding gloves if you have them), nonflammable protection for your arms and body and face guard. That may sound like a little overkill, but on the rare chance you have a spill that ignites, you will be glad you went to the the effort. Don't forget it is the fumes that ignite, not the gas so a well ventilated area is the best place to do this. If you are the least uncomfortable with this, have a professional mechanic do it. CAUTION and SAFELY are the best approach.

Good luck,

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#5 nelbur


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Posted 08 September 2011 - 02:00 PM

Leaking gas tank is a common problem with Broncos. Salt and sand gets between the skid plate and the tank and rusts the tank through. The best advice is to siphon out ALL of the gas so the tank is manageable. It is possible to clean the tank off and use epoxy and a bit of fiberglass to repair it, but the second time mine leaked, I used a new tank that I painted in the vulnerable area to help slow the corrosion.
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#6 jlick


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Posted 14 September 2011 - 02:33 PM

Well i got the tank out and patched the little pinhole that was in the side of it. Now the stupid little 2 inch round plug that goes in the top towards the center wouldnt go back in. So i tried to pull the hose off and take the tank out and try to get it in. Well the hose ripped and it has a smaller plastic hose inside it so i cant just slide it back on. I got the plug in the hole tho and im so fed up with thia damn fuel tank im about to say screw it and put it back together and just not hook this hose up. Any suggestions? Im about to just roll the pos off a cliff

#7 nelbur


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Posted 14 September 2011 - 03:45 PM

I'm not sure I understand your problem, but if you need the outside fill hose, I got mine years ago from The Bronco Graveyard. It is actually a molded hose. The inner hose is a vent hose, I believe.
'86 302 EFI

#8 Bronco Kid!

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Posted 16 September 2011 - 06:36 PM

im pretty sure that 2 inch plug your talking about is your vent and the hose goes to another hose that runs up the passenger side frame rail.. you only realy need that hose if you are taking the thing through some pretty deep water

#9 El Bronco

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Posted 01 December 2011 - 05:16 PM

I just replaced my tank earlier today. I snapped the supply line end off so I got a new one, cut part of the old line off and used the connecter that came with it. I put 2 gallons in then it started right up after a couple seconds and ran for about 6. Now it won't start at all. What could I have done wrong? I looked and everything is on properly. The only thing I can think is that it's not getting enough gas through the little joiner/connecter that I put on or the pump went bad when I had it out.
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