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Gas leak when filling tank 700 1989

Hello,

Hope all is well in your neck of the woods. I have noticed some gas leaking from the front-middle and front-left edge of my gas tank when pumping gas. This leak may be especially bad when the gas nozzle is not straight while pumping, I'm not certain though. There is no leak otherwise, just when I'm filling. The tank was not yet full at the time of leakeage. Can you help? What are the dangers?

Thanks,

Jake








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    Gas leak when filling tank 700 1989

    I'll go with George's theory that the plastic collar on the tank sending unit has not been properly installed, presumably after removing it to change the pre-pump. Look for signs of fluid stains on the (front) side and top of the tank. Even if no gas has been running out, there will be a strong gas odour, especially after a recent fill-up on a warm day.

    If the collar is too loose it will obviously allow a leak, but that's not necessarily the problem. The big rubber gasket on the sending unit that fits inside the neck needs to be seated flush before putting the collar on and tightening it. The collar often doesn't have enough strength to force a crooked gasket to seat. If there is a noticeable gap between the inside of the collar and the face of the sender then this is very likely the problem. In any case, it's very easy to have this happen especially when working through the access hatch, well at least for me.

    If the collar is forced it will easily expand and the threads will jump and start to strip before it is adequately tight. Although the spec says to just hand tighten the collar, I like to tap it an extra 1/8 turn when working through the access hatch as it's awkward to get a real good hand grip. Don't try to go much more than this or you'll start to jump threads. If the threads do get stripped, and it easily happens, you're supposed to replace the collar, but the following tip often works well.

    Is there a ring clamp around the outside of the collar? My '89 didn't have one, but my 940 does. If not, go get a stainless steel one from your local hardware store, a 5" one as I recall (Home Despot had it). Partially tighten the ring clamp before hand tightening the collar to prevent the collar from expanding and jumping threads. Do the final tightening of the ring clamp after the collar is tight.








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      Gas leak when filling tank 700 1989

      Clear and excellent directions, Dave. Didn't have time yesterday to spell it out as you have, and the clamp idea's new to me. Thanks.








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    Gas leak when filling tank 700 1989

    Assuming the '89 tank's the same as the '90, which is plastic, the big screw collar atop the tank, through which the fuel and electric pump lines run, may not be as tight as it should be. Or, if the in-tank pump was ever replaced, the collar with its big o-ring may not have been threaded right. It's easy to screw up. My '90 wagon had slight leakage and/or gas odor, though only when filling up. When I had to replace the in-tank pump, I reassembled everything correctly and no more gas leak.







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