Fuel tank issues

Topic: Fuel tank issues (Read 10950 times) previous topic - next topic

Fuel tank issues

October 12, 2011, 07:41:33 PM

Hello everyone. First time poster and newbie to car repair. Essentially I'm a computer geek, but I'm trying to bridge over into the mechanical realm as well. My main goal is to completely restore my T-Bird, but that's a long term goal. Right now I just need it working.

Okay with that aside, I have an 88 T-Bird Turbocoupe. I just dropped three grand into the engine, but a month later it has died again. After talking with several mechanics, we came to a consensus that it was a fuel issue. My current objective is to replace the fuel pump and restore the tank. Me and my dad replaced the fuel pump on my 88 Cougar three years ago, but my T-bird has a lot more rust.

Onto the details. I need to know two things before I can do this.
First, there is a second electrical connection to the tank. I have been unable to find any details or replacement parts for this. I honestly have no clue what it is, what it does, or where to find a new one. The connectors need replaced too, which I have also had trouble finding.
Second, the fuel pump and lock ring are rusted all to hell. I've had it soaking in WD-40 for a couple days, but I've had no luck. The lock ring won't budge and the rubber fuel lines won't come off. The metal just bends. Chances are I'll have to replace those lines, but I absolutely need to get the pump out if I don't want to purchase a new tank.

Here are some images I took real quick. The unit in question is on the left. The pump, in all it's rusty glory, is on the right. All images were taken from my phone and in a rushed manner so quality might not be the highest.
http://img828.imageshack.us/img828/9094/img20111012190914.jpg
http://img842.imageshack.us/img842/8721/img20111012190932.jpg
http://img802.imageshack.us/img802/1914/img20111012190921.jpg

To summarize, I need to know what that second electrical connector is to, where to find the electrical connectors themselves, and how to get the rusty fuel pump out without breaking off the tabs.

Fuel tank issues

Reply #1 – October 12, 2011, 07:47:18 PM

second connector is for the fuel level sending unit, the connectors you might have to find in a junk yard or ask a member here that is parting out a car. as far as the lock ring you might have to let it soak and try working the ring back and forth to free it up with a hammer and chisel.

Fuel tank issues

Reply #2 – October 12, 2011, 07:54:22 PM

hmm.. don't know why your lines won't come off, you removed the plastic clips so they should pop off with relative ease..

Fuel tank issues

Reply #3 – October 12, 2011, 08:11:18 PM

you will need the special disconnect tool for the return line.....

Fuel tank issues

Reply #4 – October 12, 2011, 08:17:34 PM

Quote from: Shadow;369967

hmm.. don't know why your lines won't come off, you removed the plastic clips so they should pop off with relative ease..

my lines were permanently rusted to the nylon, and wouldn't come off too

Fuel tank issues

Reply #5 – October 12, 2011, 08:18:52 PM

rock auto sells the locking rings and hanger assembly

Fuel tank issues

Reply #6 – October 12, 2011, 08:20:41 PM

those pics look exactly like mine... even the broken connector for the wiring

Fuel tank issues

Reply #7 – October 12, 2011, 08:31:15 PM

Thank you for the expedient responses.

That's one mystery solved. I'm assuming finding that particular unit would be a major pain, so I'll try to reuse the one that's there if possible. The only issue is the rust; I'd hate for it to go out in the future. Plus I need to get it out to clean and coat the tank, which probably won't be easy or forgiving.
I'll keep working on that lock ring, but I've already destroyed one tab. I'm switching to a block of wood instead of a chisel for now. Maybe a couple days of pounding and soaking will loosen it out enough.

I'm clueless as to how the lines got stuck on as well. I've yanked and tugged on them quite a bit, but all I've succeeded in doing was bending the steel pipe a little. I'm thinking I'll just cut them off and replace them. Whatever is causing them to stick probably destroyed the o-rings anyways.

Also, what tool might that be? If I know what I need, I can make one or just improvise. I did not need a special tool for my Cougar, so I've never heard of it.

I doubt they're exactly the same. If they are, here's another one showing a self mod we did. We welded on a drain/fill plug to the differential about a year and a half back.
http://img193.imageshack.us/img193/5268/img20111012202803.jpg

Fuel tank issues

Reply #8 – October 12, 2011, 08:56:28 PM

to coat the exterior of the tank, use POR 15.. it works amazingly.. just give the tank a nice scuff down with 220 grit sand paper or a wire wheel on a grinder and coat it.

Fuel tank issues

Reply #9 – October 12, 2011, 08:58:22 PM

Quote from: 88turbo;369969

you will need the special disconnect tool for the return line.....

at the tank? you sure? after popping the plastic clips off mine, they both slid right off with little to no effort.. and that's on all the fox cars i've owned

Fuel tank issues

Reply #10 – October 12, 2011, 09:17:12 PM

the lines do have clips, and should pull off.

Fuel tank issues

Reply #11 – October 12, 2011, 09:28:26 PM

Quote from: Shadow;369976

to coat the exterior of the tank, use POR 15.. it works amazingly.. just give the tank a nice scuff down with 220 grit sand paper or a wire wheel on a grinder and coat it.

I actually have a POR 15 restoration kit for the inside. I just planned on using a cheap paint on the outside. POR 15 is expensive.

Fuel tank issues

Reply #12 – October 12, 2011, 09:33:25 PM

at the price of Por 15... why not just buy a new tank?

Fuel tank issues

Reply #13 – October 12, 2011, 09:35:37 PM

Looking at the tank and sender it is SHOT. Could be wrong but i dont think so. Tank and pump ass is still available. Fuel sender is obsolete. But you can make one quite easily. I have dun many. The tank is like 120 bucks +or - abd the fuel pump ass is app the same. Start looking on line for a used good unit. They are available. Good Luck

Fuel tank issues

Reply #14 – October 12, 2011, 09:39:33 PM

you can still buy it by the pint, can't you? it's been a long time since, but my dad bought a pint of gray when he swapped the frame in his cutlass.. a pint was enough to cover the entire tank