A while back I posted about my rusted tank and got some good suggestions about it possibly being hoses. Turned out that the tank was rusted through (as was the tank skid plate which was obvious, plus many other things that weren't as obvious).

Well, I finally was able to buy all the parts I needed and get around to doing the installation (the removal took forever due to lack of time and horribly rusted bolts).

Yesterday I installed the sender into the plastic tank I got, and the fit wasn't very nice, but I eventually got it, the gasket, and the two holding-plates put on.

My concern is that water is going to sit there quite a bit, since it's got a little depression there, and the only metal parts for the tank are right there as well. Does anyone have a recommendation for protecting that area? I was thinking of maybe caulking the whole area, but I don't know if gas fumes (if the seal isn't very good) will react with it.

The other issue I'm having is the liquid check valve and rollover check valve are a bit old and destroyed. I don't see stock replacements anywhere. I'm wondering if I can use one of the rollover check valves I've seen sold on some of the racing parts sites. They look a lot different though. Anyone have experience replacing those parts?

Thanks!
-Ron <img src="/forums/images/graemlins/zombie.gif" alt="" />

Ron,

I believe that Four Wheel Ddrive Hardware (800-333-5535) has the gas tank /valve parts that you want.

I checked out their parts online, didn't see either one of them, so I called them up. The guy said they didn't have them and that he just ripped his out and uses a gas cap that vents. That would probably work for me too, especially since I can't find a replacement EGR tube, so there's almost nothing connected to my vapor canister except the tank. Not sure what I want to do there.
-Ron <img src="/forums/images/graemlins/zombie.gif" alt="" />

Well, that's ertainly one solution -- in fact, that's what I did when I installed the polyethylene tank in my CJ-7 about 12 or 13 years ago. The previous owner had totally removed the gas tank, and used a pony beer keg in the bed for a gas tank for sand drags. When I installed the plastic tank, I had to get a new sending unit, etc. I just used a "U" shaped piece of small hose and connected the two "valve" outlets to each other, and used a vent-style gas cap. Seems to have worked well for over a decade.

Regarding the non-tight fit of the sending unit. I don't know what to say there -- the new parts fit perfectly on my tank, and the sending unit works good. Indicated low for a while, until it got fully saturated with fuel. But no leaks of gasoline, and no entrance of water into the tank, despite some deep water crossings. If you don't trust yours not to leak, I would think that RTV would probably seal it good enough.

It's not so much the seal that I'm concerned about, but the inevitable sitting water rusting out the metal parts there. My concern was getting something that gasoline won't eat. According to a couple of sites, gasoline eats at least most RTVs. Some say gasoline 'resistant', but I don't think I will trust that term, since we all know what water 'resistant' watches are like.

Anyone else have an idea for a good filler for that area? I wouldn't be opposed to almost anything as long as I can at least partially remove it if I need to replace the sending unit.

-Ron <img src="/forums/images/graemlins/zombie.gif" alt="" />

I wouldn't worry about the standing water in the circular depression over the sending unit location. I put mine on about 12 years ago, and I've never had a problem. I think that anything you do to try to totally keep water out of there is more likely to trap water in there.

If you're concerned about the metal ring and other parts rusting, I'd just clean them up good and give them several coats of Rustoleum.