3 new gas tanks...3 IDENTICAL leaks. What's going on here?

[tropikal777]

Over the past two years I've had a leaky tank problem in a 94 Corolla that's been driving me CRAZY. Here's the story:

The original tank punctured (somehow) so I went ahead and ordered a reaplacement tank form Spectra: http://shop.advanceautoparts.com/web...S_753244830___

Had the tank installed, and 6 months later I started smelling fuel again. Looking under my car I find a puddle of gasoline. The car was rapidly losing fuel, which was spreading out all over the bottom of the tank, but intially there was no visible leak. I was finally able to notice a small outward pinch in the bottom of the tank almost directly above the exhaust pipe and discovered this was my leak. The actual hole wasn't even visible to the naked eye, but wiping the tank with a dirty rag showed the fuel was coming from the apex of the pinch. This pinch was not there when the tank was installed.

I removed and returned the tank which was covered under a 3-year warranty. Installed the new tank, and to make a long story short, exactly 6 months later I had THE SAME, IDENTICAL LEAK.

Make along story short, it's now exactly 6 months later and the same thing has happened all over.

My first thought was the tank is defective. After contacting Spectra, I heard two different stories:
- A Spectra employee at a US distributor told me Spectra is aware of the problem but is doing nothing about it.
- An employee at the Spectra warranty claims department said I must have pressure problem with my tank, and that expansion and contraction the tank itself will cause the metal to crease at the spot of the leak, which is the weakest point in the tank.

A mechanic and a Toyota dealer service department have told me the expansion/contraction explanation is utter bull$--t. And I have NOT had any warning lights indicating pressure issues.

Ideas/explanations anyone??? Should I try another band of aftermarket tank? Or is there something else going on here?

[zythr]

You answered your own question. You try a reputable company that makes replacement gas tanks. You did not mention how much you paid for the ones you bought, but obviously they're of low quality. The guy tipped you off when he mentioned the expansion/contraction of the fuel could cause your leaks. Well made gas tanks are designed for this, cheap ones aren't.

[PhatRoyale]

My hunch is the inconsistency and low quality of aftermarket gas tanks.

Buy an OEM Toyota gas tank.

[Bitter]

make sure you're not crushing it with the straps and that your EVAP system lines are not pinched between the tank and body and the EVAP system is venting properly.

[speedy25]

ALL aftermarket parts should be of the same quality of the OEM part or better. Of course we know that isnt always the case, especially here.

As you have found out their "warranty" is essentially useless. Start with a written letter asking for a full refund for all you have spent on the piece-o-crap and further file complaints with BBB and your stae attorney general and their states attorney general. I'm sure there is a federal agency that would want to hear your story too but I dont know which one.

Having a continuously defective fuel tank should get their attention easily. Of course this is a VERY hazardous health and safety issue for YOU as well as others in your vicinity.

I hope you still have some money left over to get a good tank that doesnt leak.

-SP