Looking for a little advice on a fuel tank venting/leaking issue on my '94 FJ80.

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Joined
Feb 10, 2026
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Location
az
I'm pretty sure my charcoal canister has gone bad, and I'm about to replace it with a VC-120. The tank builds a lot of pressure, and when I crack the gas cap there's a pretty good hiss. I'm in Arizona, so the extreme heat probably isn't helping.

The truck sat for a few days while I replaced the brake booster. When I came back, it had started leaking fuel somewhere around the tank. It's dripping off the gas tank skid plate, but I can't tell where it's actually coming from. If I let the pressure build up, I can hear fuel or vapor escaping and it'll leak until the pressure drops, then it stops for a while.

I pulled the access panel above the tank, but everything I can see from the top is dry. I'm thinking it's probably a hose or fitting that I can't see without dropping the tank. It'll also leak even when the tank is below 1/4 full.

A few questions:

  • Is there any kind of pressure relief valve on these tanks that could be venting fuel?
  • Are there any common places these tanks leak under pressure?
  • Can enough pressure actually force fuel past an otherwise good seal or hose connection?
  • The tank itself looks to be in good shape with no obvious rust. Anything else I should be checking?
My concern is that once I replace the charcoal canister and the tank can vent again, I won't be able to reproduce the leak. Would you guys drop the tank and find the leak anyway, or replace the canister first and see if the leak goes away?

Thanks!
 
@JBC90 ,

Mostly likely you have a crack in the fuel tank. Very common problem. I suggest reading this thread....
 
They can crack at the top of the tank due to the pressure. Happened on my 96. Used JB weld to repair it a few months ago. Holding so far.
 
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