My 95 Legacy AWD Wagon gas tank need to be replaced. I thought it was going to easy to fix by replacing the inlet pipe. Couldn't get that lucky. It is leaky at the top inlet neck of the tank.It looks to be a fairly involved job of dropping the entire rear drive train and then dropping the tank. It is 10 years old and 172000 miles so welcome to salt in the north east.Any idea on how many hours this should take and anything to be aware of.

If you have everything there, and don't run into any major issues, you should be able to do it in a day....albeit a long day. It definitely helps a lot to have an extra set of hands to help steady the tank as you drop it.

 

Easiest thing to do is drop it a little bit, so you can loosen the lines going to the engine from the tank. Make sure you label which line goes where. Do the same when removing the filler neck and vent lines.

 

There are two bolts on either side of the tank to drain it.

How bad is the leak??

I am about to embark on a ?repair of the inlet pipe. It rusted out at the usual spot, right at the bottom of the bend where sand and salt cake up inside the "protective" cover.

I found an epoxy kit at Advanced Auto and Also at Autozone that requires LIGHT (KABOOM) sanding, pretreatment with alcohol (the metal not the operator) and application of epoxy and mesh. It's less than $10 and I figure it's worth a try since those darn phillips screws holding the filler tube in are as tight as... well they're real tight. It's a '91 and has seem many a Northeast winter.

Well I tried the gas tank repair epoxy from Autozone $3.00 and it seems to work as advertised. It's a two part putty where you knead the two parts together and just press it onto the area to be repaired which should aready be sanded and cleaned using a brake degreaser or other cleanser (check package).