Troubleshooting Fuel Tank Leak

[Ccrand88]

Hi All,

Recently bought a new to me 1996 Land Cruiser and noticed that it leaks gas when I fill it at the pump. I'm trying to troubleshoot what the root cause / solution might be and was wondering if anyone else has experienced the same issue I am having. I got under the truck to check around the tank and noticed it was coming from the fill line/gasket area and only seems to leak when the truck is specifically being filled. While I am pretty confident this is either down to the fuel fill and breather hose (PO seems to have tried adding more clamps to solve the issue) or the fuel fill gasket, I was wondering if there may be any other sources I could be missing. It also looks like the charcoal canister has been replaced with an aftermarket unit but I have not been able to test it yet. Ive attached some pictures I took where the fuel fill and breather lines meet the tank. The tape on the breather line was also from a hasty "repair" I made when I had filled the truck after I bought it, but I have another picture showing that it also seemed to be leaking out some gas (the main fuel fill area was also leaking like shown in the first 3 pictures during this) which makes me wonder if the tank is breathing properly.

I would appreciate any advice or insight you can offer.

 

[ppc]

There are several threads about leaking tanks.

An example: Cracked fuel tank #2 - https://forum.ih8mud.com/threads/cracked-fuel-tank-2.899886/page-3

 

[Ccrand88]

For anyone else who ends up with a similar issue to me, the issue ended up being the fuel fill and breather hoses as I had suspected, not the cracked tank issue that some people seem to have. The previous owner put in a poor quality replacement that eventually broke and started leaking whenever it had to carry gas from the fill hard lines to the tank. I was able to pull both of the lines out after fighting under the truck for a few hours and replaced them with OEM replacements from PartSouq (P/N 77213-60090 for the main hose, 95311-13022 for the breather). Not a fun job to do with the cramped access space and cross-member in the way. I would recommend anyone trying this in the future to lube up the connections for both lines a bit before putting the new hoses on since the new rubber grips very well. It may also just be easier to drop the whole tank and have easy access to the lines and everything else on the tank, but I didn't have the tools or space to do it myself.

 

[BILT4ME]

For anyone else who ends up with a similar issue to me, the issue ended up being the fuel fill and breather hoses as I had suspected, not the cracked tank issue that some people seem to have. The previous owner put in a poor quality replacement that eventually broke and started leaking whenever it had to carry gas from the fill hard lines to the tank. I was able to pull both of the lines out after fighting under the truck for a few hours and replaced them with OEM replacements from PartSouq (P/N 77213-60090 for the main hose, 95311-13022 for the breather). Not a fun job to do with the cramped access space and cross-member in the way. I would recommend anyone trying this in the future to lube up the connections for both lines a bit before putting the new hoses on since the new rubber grips very well. It may also just be easier to drop the whole tank and have easy access to the lines and everything else on the tank, but I didn't have the tools or space to do it myself.

View attachment 3715236

What did you use for clamps? Did you get rid of the worm gear clamps and buy new Toyota as well?

 

[Ccrand88]

What did you use for clamps? Did you get rid of the worm gear clamps and buy new Toyota as well?

For the fill hose the diagram calls for worm gear clamps. Got new ones from partsouq as well but they only sent me one so I reused the other worm clamp that was on the old hose. For the breather clip clamps are called out, but the original ones were out of stock so I tried to get some I thought would be equivalent but they weren’t the right size. I ended up also reusing the worm clamps for the breather, and they seem to work fine even if they aren’t ideal.