Gotta repair my fuel tank

[BrianMDTX]

Been in Texas for four years this month, but my ‘05 Dodge Ram 1500 still bears the scars of 14 years of Maryland and road salt. Had an EVAP leak. Found out the lock ring for the fuel pump totally disintegrated from corrosion. As well as the steel studs integral to the tank that the lock rings attach to. So…either spend $800-$1000 for a new fuel tank plus a new fuel pump and lock ring, or repair the current tank? But how?

 

Well, thank the gods above for Google, as I found out there is a company called Gas Tank Renu that sells a repair kit that allows you to install a fuel pump with a large, flat ring with self-tapping screws and sealant for less than $50.00! Still have to drop the tank, but total cost with a new pump (old pump still works but with 177K miles on it, I’d be a fool to reinstall it) will be less than $300.00. Big difference! The repair kit is on the way, so time to drop the tank, prep it (have to grind down any remaining stud remnants to flush) and clean the tank out and get ready to install the kit. I’m sure it will be the last fuel pump I ever install on it lol. 

[TOXIC]

I didn’t think that Maryland was a big salt state due to it being on the Chesapeake watershed.  I know here in Virginia we don’t use a lot of salt but there is a brine.  My 2004 2500 Silverado I bought new in Virginia and traded in 2016 didn’t have a speck of rust anywhere on the body and the frame/undercarriage was pretty rust free.  I’ll go ahead and say it……..weren’t those older Dodge trucks known for rust? Good on you for finding a cheaper fix. 

[GreenPig]

I've got a couple chevrolet owning friends that swear lifting the bed for fuel tank work is easier than dropping the tank. 

[BrianMDTX]

Dodges were known for fender rust inside to out. That’s for sure. And Maryland uses a lot of brine now, but when I first got the truck they used megatons of salt. 
 

Removing the tank solo requires a floor jack. The bed? You have to have a crane or gantry hoist, unbolt the bed, disconnect the wiring for lights, etc.  I’ll have the tank dropped and the repair underway before I got the bed ready to remove lol. And definitely not a solo job at almost 63. 

[BrianMDTX]

Man, not an easy job solo, but I got it down, repaired and installed. There was a ton of rusted metal inside the tank. Had to wash the tank out three times after siphoning out the last 1/2 gallon of remaining fuel to flush all the rust particles out. Other than that, the tank was very clean inside. Most of the lock tabs were thoroughly rusted but still had a bit of grinding to do for the ring to fit flush. Finished the repair and installation of the new fuel pump at 4:30 yesterday and let the sealant cure overnight. Pressure checked it with shop air and leak detector this morning and no leaks. Took about two hours to install the tank. The rear strap was a true pain to get lined up on the stud. Put some fuel in it and she fired up quickly. $202.99 for a new pump and $65.00 for the repair kit + shipping vs $800.00-$1000.00 + for a new tank and pump. No fishing this weekend but I’m back in the saddle again! 
 

[TOXIC]

Always amazed at what mechanical minded guys can accomplish.  My buddy who helps me work on my truck/boat isn’t afraid to tackle almost any job.  His saying is that if a man built it, he can tear it apart and fix it. ?

[BrianMDTX]

@TOXIC Gotta admit, I was a bit apprehensive about attempting this repair. I’m no spring chicken anymore, and once started, it was either finish it or call a wrecker. I used a floor jack to support the front and a ratchet strap on the rear. It worked, and well I might add. But I wouldn’t want to do it again lol!