Fuel tank leaking

[skipsor]

I picked up my coach, a 2004 Winnebago Brave, at Redlands Truck Service today and Keith showed me a leak in the gas tank at a spot weld location. I'm not familiar with gas tank construction but the spot welds may be for internal baffles. There are two rows of these welds several inches on either side of the filler neck.

This, to me, is more troubling to me than the brake problem because with the right set of circumstances the coach could catch fire while underway. Obviously this could very rapidly become a life threatening, catastrophic event.

Apparently mine is not the only tank they have seen with this problem and Workhorse would not cover it under the emissions control warranty. This is a very obvious leak and it appears as though there are pinholes in the spot weld.

It would be interesting to find out if this is a common problem or an isolated incident. It would definitely be in everyone's best interests to inspect your tank for this condition.

[TXiceman]

JB Weld makes some epoxy products that will stand up to gasoline and oil. It would be worth a try to "patch" it yourself.

Sand the area around the leak with a 80 grit sand paper and wipe down with a clean rag and alcohol. After this has air dried, mix the JB Weld and press it on to the area to patch. I have patched a cracked intake manifold on a 5 HP Johnson out board and it was running fine 4 years later when I sold it.

Ken

[Midniteoyl]

Gas Tank RENU - USA

[DriVer]

Quote:

Originally Posted by skipsor This, to me, is more troubling to me than the brake problem because with the right set of circumstances the coach could catch fire while underway. Obviously this could very rapidly become a life threatening, catastrophic event.

I replaced my tank a couple of years ago. They just go bad after awhile I guess. Mine began leaking under the straps. The tanks are made out of steel and are not indestructible. I have a 2003 coach. You can have several scenarios with steel tanks, full weight then no weight, expansion, contraction, condensation, sudden bumps in the road, water, environment and wear and tear.

[DAN L]

Quote:

Originally Posted by skipsor I picked up my coach, a 2004 Winnebago Brave, at Redlands Truck Service today and Keith showed me a leak in the gas tank at a spot weld location. I'm not familiar with gas tank construction but the spot welds may be for internal baffles. There are two rows of these welds several inches on either side of the filler neck. This, to me, is more troubling to me than the brake problem because with the right set of circumstances the coach could catch fire while underway. Obviously this could very rapidly become a life threatening, catastrophic event. Apparently mine is not the only tank they have seen with this problem and Workhorse would not cover it under the emissions control warranty. This is a very obvious leak and it appears as though there are pinholes in the spot weld. It would be interesting to find out if this is a common problem or an isolated incident. It would definitely be in everyone's best interests to inspect your tank for this condition.

i would try the jb stick weld.
J-B Weld Company - J-B STIK Product Information

[ron55]

ETAHNOL is eating the welds in alum boat fuel tanks causing them to leak so I guess it will eat the welds in steel tanks. Lots of problems with boats here where I am.

[gg]

I had good luck using the J-B weld on a 1980's steel gas tank that had rusted on the top half. sold it 3 year later and was in good shape. I ran the gas down to 1/4 tank and did the patch on the vehicle.

gg

[DriVer]

If the fix holds that's as good as a new tank.

Tank you very much.

[lakewoodpaul]

I had a leak at the same spot on my 03. 3 members of my WIT chapter had the same problem, all were fixed under emissions warranty, that was a few yrs ago. Check your warranty [emissions] I thought it was a 7yr. warranty not sure tho.

[Midniteoyl]

JB weld is epoxy and epoxy doesnt do well with fuel, especially achohol. Oh it'll last for a while, but it could be 30 days or 3 years depending on the amount, thickness, quality of repair, where the leak is (top of tank is better than bottom), etc..

Up to you.

[DriVer]

Quote:

Originally Posted by lakewoodpaul I had a leak at the same spot on my 03. 3 members of my WIT chapter had the same problem, all were fixed under emissions warranty, that was a few yrs ago. Check your warranty [emissions] I thought it was a 7yr. warranty not sure tho.

RTS would have told him is there was any recourse to pursue or if there were the possibility that the emissions warranty would kick in in this case. Keith don't miss much.

[Duner]

Kieth at RTS changed my 2004 leaking gas tank 2 yrs ago. It was replaced under emissions warranty just one month before the 5 yr time ran out.

There are a lot of tanks leaking that were made around the 2003/2004 time frame.

There are several baffles inside. Looking at the spot weld that failed in relation to the straps that hold the tank in place, I think that there is additional stress at that point, and possibly a vibration that fatigues the metal at this location. When mine failed on 2008, others on this forum posted about failures at the same location.

[skipsor]

Duner, I'm glad to hear that I have some company, although that's a dubious honor.

Several of you replied that you have repaired leaking tanks with a product called JB Weld and some of you have had good luck with it. I am not personally familiar with this product but I have seen more than my share of people who have died in automobile fires in the 28 years spent as a paramedic with the Los Angeles FD. It's not something I would wish on anyone.

A good friend who spent about 18 years as an arson investigator with the same department told me today that fuel leaks are the number one cause of vehicle fires. This is why I chose to replace the tank. Not passing judgment, just relaying some information.

[DriVer]

Quote:

Originally Posted by skipsor A good friend who spent about 18 years as an arson investigator with the same department told me today that fuel leaks are the number one cause of vehicle fires. This is why I chose to replace the tank. Not passing judgment, just relaying some information.

I was a career firefighter for 28 years and I can count on one hand fires that originated at the fuel tank. Fires will normally occur where the heat is and extend to the interior of the vehicle. Did you know that coolant is flammable and most all of the other fluids used in our vehicles are also flammable. Not to lessen the importance of having a secure fuel system, a repair may suffice and a routine examination during normal service intervals should rule out any further leaks. Our gas tanks are not easily obtained. It took me a month of more to get my fuel tank because they were out of stock. If I couldn't afford the time, I'd fix the leak now and wait for the new tank, that's how I would proceed.