damn you rust hole in fuel tank! anyone have a patch suggestion? - Toyota Nation Forum : Toyota Car and Truck Forums


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3rd & 4th Generation (1992–1996 & 1997–2001) Toyota Camry Discussion for years: 1992-1996 & 1997-2001 Topics of discussion range from fuel economy, safety, modifications, performance all involving America's favorite family car, the Toyota Camry.

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Old 01-18-2010, 11:49 AM   #1 (permalink)
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damn you rust hole in fuel tank! anyone have a patch suggestion?

two weeks ago i finally replaced the filler neck on the 96 camry. after much cursing and a couple of sheared bolts later the old part was off and the new one installed. yesterday i filled the tank full. as i was removing the pump handle at the station there was a strong odor of fuel followed by a small gas stream coming out from under the car. last night discovered where the vent tube connects to the fuel tank, there is a 1/4" rust hole in the weld.

question to all of you - in my rummage through the garage to figure out a patch, i decided to use some JB weld (as opposed to high temp RTV or other epoxies/sealers) - will gasolene disolve JB Weld? is there something else to consider or should i be shopping for a new tank?

being that i have a backup vehicle if really needed, i am also considering dropping the tank, draining the fuel, airing out the tank and possibly welding it. anyone have experience welding a fuel tank?

i drove the camry today but cant tell if its leaking or not. everything is either wet from the roads, metling snow or condensation.
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Old 01-18-2010, 12:49 PM   #2 (permalink)
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JB-Stick is what you probably want to use then...

Have you thought about using a gas tank sealer? POR-15 makes one that is second to none.
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Old 01-18-2010, 02:05 PM   #3 (permalink)
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Old 01-18-2010, 07:31 PM   #4 (permalink)
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if its a whole caused by rust the only good solution is replacement. if it is leaking even slightly(sweating) that mean rust is exposed to the gas and not only will the gas speed up break down of the metal but it will put minerals in the fuel you dont want. Id find a replacement asap.
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Old 01-18-2010, 08:21 PM   #5 (permalink)
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flood the tank with argon before you weld, or else, kaboooom
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Old 01-18-2010, 09:11 PM   #6 (permalink)
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Fuel leak is dangerous. REPLACEMENT would be the proper fix. However, you can temporarily patch it up using Permatex Instant Gas Tank Repair compound:

http://www.permatex.com/products/Aut...ank_Repair.htm

A new tank online is about $188 + shipping:
http://www.rockauto.com/catalog/moreinfo.php?pk=534579

Or you can get the EBay one for $150 shipped.




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two weeks ago i finally replaced the filler neck on the 96 camry. after much cursing and a couple of sheared bolts later the old part was off and the new one installed. yesterday i filled the tank full. as i was removing the pump handle at the station there was a strong odor of fuel followed by a small gas stream coming out from under the car. last night discovered where the vent tube connects to the fuel tank, there is a 1/4" rust hole in the weld.

question to all of you - in my rummage through the garage to figure out a patch, i decided to use some JB weld (as opposed to high temp RTV or other epoxies/sealers) - will gasolene disolve JB Weld? is there something else to consider or should i be shopping for a new tank?

being that i have a backup vehicle if really needed, i am also considering dropping the tank, draining the fuel, airing out the tank and possibly welding it. anyone have experience welding a fuel tank?

i drove the camry today but cant tell if its leaking or not. everything is either wet from the roads, metling snow or condensation.
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Old 01-18-2010, 09:27 PM   #7 (permalink)
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There is no FIX for a rusted out fuel tank. If it's rusted through in one spot, it's paper thin in many others. Replace it and be safe!
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Old 01-19-2010, 01:06 PM   #8 (permalink)
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thank you all for the suggestions and tips. i think i will get a replacement tank. i dont feel safe carting around my kids in a potentially un-safe vehicle. i will probably scour the local salvage yards for a uesd replacement before ordering new. feels like im rebuilding the camry one piece at a time.

does/did anyone else have their tank rust though? havent heard of this from anyone with a camry.
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Old 01-19-2010, 01:17 PM   #9 (permalink)
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Hmmm and i always thought these had plastic tanks. Im gonna check my 98 next time i have it up in the air.
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Old 01-19-2010, 07:35 PM   #10 (permalink)
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After flooding it, sand down and solder in a patch.
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Old 01-19-2010, 09:45 PM   #11 (permalink)
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you pull it yards punch the tanks with a brass punch to dump the fluid to make it enviro safe?

not sure 100% but if so

http://www.car-part.com
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Old 01-20-2010, 02:51 PM   #12 (permalink)
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I have brazed steel gas tanks with brass filler. Removed fuel and fuel sender, filled tank with water.

Beware that Rustproofing or undercoating smokes alot if it catches fire.
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