Gas tank help 01 XL 2500 - The 1947 - Present Chevrolet & GMC Truck Message Board Network

SKELLY4x4 · 10-08-2005, 06:24 PM

So, my forward gas tank, which happens to be plastic decided to start leaking. I'm not sure how that could happen suddenly at 60K miles and right after I just serviced it with some love. Anyways, a replacement is "not readily available" from GM. I'm looking for a used one in San Diego and none of the junkyards have one either. Am I the only person in the world that's had this issue? I've got 3 kids and my wife is driving the kids around in my 89 extra cab dually which right now doesn't have running lights and I'm stuck in Alaska on business so I can't troubleshoot the dually. I have a few options. 1. Have a custom tank built. 2. Rent her a car while the dually is in the shop. 3. Find a used gas tank and have a shop put it in. I want #3 mostly. Anybody happen to have one laying around near San Diego?

SKELLY4x4 · 10-08-2005, 06:49 PM

just checking out my new signature...

Joe67 · 10-09-2005, 12:53 PM

This is the first time I've heard of a NBS (New Body Style) truck tank leaking. Being it's plastic, are you sure it isn't he Ring on top that keeps the sending unit in place?

Sounds like shopping for a used tank may be your best bet since they do not appear to be available from GM right now

SKELLY4x4 · 10-10-2005, 03:04 PM

It leaked about 15 gallons, which is about half the capacity. I am pretty sure it is leaking on the seam, which is about halfway on the tank. Glad it didn't blow up on the wife after she filled it up. There was no warning, it just started leaking badly. Maybe the fuel cap isn't venting or something and the heat expanded the tank??? Who knows, gonna call gm customer service and see what they have to say about it.

Joe67 · 10-10-2005, 03:06 PM

Quote:

Originally Posted by SKELLY4x4

It leaked about 15 gallons, which is about half the capacity. I am pretty sure it is leaking on the seam, which is about halfway on the tank. Glad it didn't blow up on the wife after she filled it up. There was no warning, it just started leaking badly. Maybe the fuel cap isn't venting or something and the heat expanded the tank??? Who knows, gonna call gm customer service and see what they have to say about it.

Sounds like the way to go. Keep us posted.

SKELLY4x4 · 11-02-2005, 12:16 AM

I was able to find a used tank in Minnesota. Keep your fingers crossed for me, I'm not sure it's legal to ship a gas tank but it's supposedly on the way to San Diego.

99-2door · 11-03-2005, 06:43 PM

Damn... I throw those things away all the time. Nobody ever wants to buy them.

Oh...BTW the cap is not supposed to vent on a NBS.

SKELLY4x4 · 12-03-2005, 02:42 AM

Just an FYI on the problem. I got a new used tank from Minnesota and it was fine and all. I pulled the old tank out and found that there was nothing wrong with the tank. I scratched my head, figured maybe that it was the o-ring on the fuel pump / fuel level sending unit because that was where it appeared to be leaking, but it looked perfect. Went to Poway Chevrolet looking for a new o-ring. He sold me one for 10 bucks and sent me to talk to his tech. Turns out that this is actually a pattern failure and there's a campaign on the 1/2 ton trucks/tahoes/suburbans

. Mine is a 3/4 ton suburban, which there are a lot less of, so there's no dealer updates/campaigns. What actually happens is that as the fuel pump ages, it starts to draw more current than the wires/connections for it are designed for. The power wire at the fuel pump gets warmer than it's supposed to and then eventually the connector on the top of the sending unit that connects the truck to the fuel pump gets hot, which melts just enough to dis-form and it leaks there. So, at 60K miles, the bastard truck leaks fuel when it's full. See, it's got 2 tanks, the rear tank holds about 12 gallons. It's above the main tank, so it just gravity feeds into the main tank. The sending unit connector leaks until the rear tank is empty. Anyways, I have a stinking suspicion that this will be one of those Chevy problems that everybody and their mother knows about eventually. It costed me 125 bucks for a tank I don't need, thank god I didn't buy a new one for 600, and 10 bucks for an o-ring that I didn't need, and then the fuel pump / fuel level sending unit that costed about 200 bucks that I did need and was the problem. Also, since this could be interpreted as an "emissions problem" it may be a warranty item. Mine was past warranty but I've heard that emissions issues may have warranty up to 100K miles. Either way, check around before you waste your time/money on this issue. Also, hats off to Poway Chevrolet in San Diego, CA for letting me talk to their tech, who knew WTF he was doing and refused to take my money for his advice. I'll buy my next new car from them for sure.

10-08-2005, 06:24 PM	#1
SKELLY4x4 Registered User Join Date: Jan 2001 Location: RAMONA, CA, USA Posts: 94	Gas tank help 01 XL 2500 So, my forward gas tank, which happens to be plastic decided to start leaking. I'm not sure how that could happen suddenly at 60K miles and right after I just serviced it with some love. Anyways, a replacement is "not readily available" from GM. I'm looking for a used one in San Diego and none of the junkyards have one either. Am I the only person in the world that's had this issue? I've got 3 kids and my wife is driving the kids around in my 89 extra cab dually which right now doesn't have running lights and I'm stuck in Alaska on business so I can't troubleshoot the dually. I have a few options. 1. Have a custom tank built. 2. Rent her a car while the dually is in the shop. 3. Find a used gas tank and have a shop put it in. I want #3 mostly. Anybody happen to have one laying around near San Diego?

10-08-2005, 06:49 PM	#2
SKELLY4x4 Registered User Join Date: Jan 2001 Location: RAMONA, CA, USA Posts: 94	just checking out my new signature... __________________ 1972 chevy k20 long bed 4x4 1990 chevy K5 blazer 2001 chevy 2500 hd 4x4 1999 chevy 1500 4x4

10-10-2005, 03:04 PM	#4
SKELLY4x4 Registered User Join Date: Jan 2001 Location: RAMONA, CA, USA Posts: 94	It leaked about 15 gallons, which is about half the capacity. I am pretty sure it is leaking on the seam, which is about halfway on the tank. Glad it didn't blow up on the wife after she filled it up. There was no warning, it just started leaking badly. Maybe the fuel cap isn't venting or something and the heat expanded the tank??? Who knows, gonna call gm customer service and see what they have to say about it. __________________ 1972 chevy k20 long bed 4x4 1990 chevy K5 blazer 2001 chevy 2500 hd 4x4 1999 chevy 1500 4x4

11-02-2005, 12:16 AM	#6
SKELLY4x4 Registered User Join Date: Jan 2001 Location: RAMONA, CA, USA Posts: 94	Re: Gas tank help 01 XL 2500 I was able to find a used tank in Minnesota. Keep your fingers crossed for me, I'm not sure it's legal to ship a gas tank but it's supposedly on the way to San Diego. __________________ 1972 chevy k20 long bed 4x4 1990 chevy K5 blazer 2001 chevy 2500 hd 4x4 1999 chevy 1500 4x4

11-03-2005, 06:43 PM	#7
99-2door Registered User Join Date: Oct 2003 Location: Broken Bow, OK Posts: 1,385	Re: Gas tank help 01 XL 2500 Damn... I throw those things away all the time. Nobody ever wants to buy them. Oh...BTW the cap is not supposed to vent on a NBS. __________________ 95 K3500 SRW 5.7L Vortec 4L80e 4.10 G80 2001 GMC C3 6.0 AWD, Volant, 3/5 drop TBSS intake, HP tuners, pullies, 05 efans, 05 front brakes, etc. 2003 Tahoe Z71 Silverado front clip

10-09-2005, 12:53 PM	#3
Joe67 67 is sold Join Date: Apr 2001 Location: Troy, Michigan Posts: 6,738	This is the first time I've heard of a NBS (New Body Style) truck tank leaking. Being it's plastic, are you sure it isn't he Ring on top that keeps the sending unit in place? Sounds like shopping for a used tank may be your best bet since they do not appear to be available from GM right now __________________ Joe - Formerly 67c10step ------------------------------- 1967 Chevy Stepside - ECE 4/6, fuelcell, 5lug - SOLD gr8lakes - My ebay auctions Click here to order forum apparel :: Click here to become a subscribing member

12-03-2005, 02:42 AM	#8
SKELLY4x4 Registered User Join Date: Jan 2001 Location: RAMONA, CA, USA Posts: 94	Re: Gas tank help 01 XL 2500 Just an FYI on the problem. I got a new used tank from Minnesota and it was fine and all. I pulled the old tank out and found that there was nothing wrong with the tank. I scratched my head, figured maybe that it was the o-ring on the fuel pump / fuel level sending unit because that was where it appeared to be leaking, but it looked perfect. Went to Poway Chevrolet looking for a new o-ring. He sold me one for 10 bucks and sent me to talk to his tech. Turns out that this is actually a pattern failure and there's a campaign on the 1/2 ton trucks/tahoes/suburbans . Mine is a 3/4 ton suburban, which there are a lot less of, so there's no dealer updates/campaigns. What actually happens is that as the fuel pump ages, it starts to draw more current than the wires/connections for it are designed for. The power wire at the fuel pump gets warmer than it's supposed to and then eventually the connector on the top of the sending unit that connects the truck to the fuel pump gets hot, which melts just enough to dis-form and it leaks there. So, at 60K miles, the bastard truck leaks fuel when it's full. See, it's got 2 tanks, the rear tank holds about 12 gallons. It's above the main tank, so it just gravity feeds into the main tank. The sending unit connector leaks until the rear tank is empty. Anyways, I have a stinking suspicion that this will be one of those Chevy problems that everybody and their mother knows about eventually. It costed me 125 bucks for a tank I don't need, thank god I didn't buy a new one for 600, and 10 bucks for an o-ring that I didn't need, and then the fuel pump / fuel level sending unit that costed about 200 bucks that I did need and was the problem. Also, since this could be interpreted as an "emissions problem" it may be a warranty item. Mine was past warranty but I've heard that emissions issues may have warranty up to 100K miles. Either way, check around before you waste your time/money on this issue. Also, hats off to Poway Chevrolet in San Diego, CA for letting me talk to their tech, who knew WTF he was doing and refused to take my money for his advice. I'll buy my next new car from them for sure. __________________ 1972 chevy k20 long bed 4x4 1990 chevy K5 blazer 2001 chevy 2500 hd 4x4 1999 chevy 1500 4x4



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