My fuel guage was reading accurately (showing only 3/4 full when the tank was filled to the brim) so I decided to change the fuel sending unit. At that time there was a smell of fumes in the cab.I changed out the fuel tank sending unit and gasket. I screwed that up as even though the gasket looked like the holes were evenly spaced, they were not (caution - when you are changing the gasket, be sure to line up the holes correctly).Unscrewed the sending unit, lined up the holes, and reinstalled the unit and still could smell fumes.My mechanic then made a new gasket out of cork and installed it and could still smell fumes.I unscrewed the screws on the top of the sending unit and put in new proper fitting screws with rubber washer and I could still smell fumes. Be careful, I torqued one of the screws down too tight and busted off the head of it.Got desperate and gobbed on some JB Weld around any gaps between the sending unit and the gas tank (including around the screws) to seal it up for good. Smell went away for about 3 weeks, but the fumes have worked their way through even the JB Weld.Threw on some clear silicone last night and the fumes are still coming through.I am a little sensitive to smells, but I just don't want me or the kids to kill brain cells while riding in the truck.I also changed out all of the rubber hoses in the cab including the filler neck hose (that made a big difference). The 5/8' venting hoses were hard to find but I was able to get some at West Marine (my mechanic used some heater hoses in a couple of spots and the fumes penetrated through those in less than a day).I'm getting desperate here.
Gas Cap Gasket in Cork gas cap gasket, cork type. 4 1/8' outside, 3' inside, 3/16' thick. For 356 Front Fill Sold per each. Manufacturer Information: We have worked on Porsche cars for a long time, and have tried most of our aftermarket products first hand on real cars.
Shoot - I might even throw on some duct tape. Did the lip on the gas tank become deformed when you over tighten the sending unit? If so, you've created a gap that will be difficult to seal. The lip will need to be straightened if it has been deformed/bent.Did you replace the cork gasket your mechanic installed with a thick, neoprene, gasket? Neoprene will seal far better than cork in this type of application. If you can't find this gasket, you can make one using a small sheet of neoprene using the sending unit as a template.Quite a few sealers are petro chemically soluble and won't stand up to gasoline.
Forrestbump wrote:Did the lip on the gas tank become deformed when you over tighten the sending unit? If so, you've created a gap that will be difficult to seal.
The lip will need to be straightened if it has been deformed/bent.Did you replace the cork gasket your mechanic installed with a thick, neoprene, gasket? Neoprene will seal far better than cork in this type of application.
If you can't find this gasket, you can make one using a small sheet of neoprene using the sending unit as a template.Quite a few sealers are petro chemically soluble and won't stand up to gasoline.It's possible that it became deformed, but I don't know - it's all sealed up now and will take some work to remove the sending unit at this point. The cork gasket is still in there - now that I know how easily these fumes can penetrate materials, I should have replaced the cork with the neoprene. Looks like I should just work on removing what I have done, get a new gasket and start over at the beginning.
70F100 wrote:Check to make sure it's not the cap leaking. They can leak and the gas will run down the filler neck through the old, cracked rubber seal and go directly into the cab.Another thought is the short hose that connects the filler neck to the tank. The hose gets old and hard, and the clamps may or may not be able to be tightened enough to seal.It's pretty tough to get enough gas up to the sending unit for it to leak, and with all you've done to it, I'd say that's probably not your issue.I replaced all of those items and they are fine - before I replaced them, they were the originals and were hardened and smelled like gas.
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