Repairing a plastic fuel tank

Question:

I have a leaking fuel tank on my 2004 Chevrolet SSR with the 5.3 Liter (LS-1) engine, automatic transmission, etc.

This vehicle has a plastic-type fuel tank. There is a plastic sleeve that goes into the fuel tank that then attaches to a rubber hose from the fuel door to the tank. The hose is OK and is fastened on each end with screw-type hose clamps.

The problem is that the plastic sleeve going into the fuel tank is loose and whenever the fuel tank is filled, gasoline will literally pour out onto the ground until it is below the level of the plastic sleeve. I realize that an easy way to stop this leak is to not fill the fuel tank all of the way and it will not spill onto the ground, but who knows exactly when to stop fueling so you won’t go beyond that level.

I have priced a new fuel tank, which this vehicle does not really need, and it will cost between $500-$600 just for the tank, not including removal of the old tank and installing the new one.

Is there some sort of sealer that will not dissolve upon contact with gasoline, or some way to seal this loose plastic sleeve without having to remove the tank? It is fairly easy to get at the leaking sleeve when the vehicle’s on a lift or ramps, and I am sure that some sort of reliable sealer would work.

Answer:

There are various sealers and adhesives that are specifically formulated to resist gasoline. PC-Super Epoxy Translucent Paste from the Protective Coating Co. in Allentown, Pennsylvania (pcepoxy.com), is one example of a gas-resistant epoxy that you can use to glue the plastic tube to the plastic tank.