Replacing 300tdi fuel tank

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lrmonks

Member
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70
I have a 1998 Defender 300tdi 90. I just noticed that the fuel tank is dripping diesel slightly at the front end. I have inspected the top and it's all dry but the leak seems to be coming from the flange joint where the two halves are welded together. Has anyone had experience at replacing one? Is it a pig or relatively easy? Anything to look out for or be aware of? Thanks in advance.
 
Yeah, don't weld it .. ;)

On my (older) 90 there's a breather tube on the fuel filler pipe, try to check how that is. It goes to the side of the fuel tank, so doesn't show a leak on top, mine was cracked at the fuel tank fitting and gave very similar symptoms of a wet looking fuel tank front.
 
Two bolts at one end and on at the other, IIRC. Jubilee clips, or similar, on the filler and breather pipes. Sender unit on the top. The nuts/bolts you'll probably end up having to grind off, so have new ones ready. New gasket and retainer for sender unit. New jubilee clips for pipes.
 
if I fill my tank to full and I mean full ,when I park up I get a drip drip drip and it stops after I've used some of the fuel, when you fill yours do you max the tank out if you do it might be whats wrong.
 
if I fill my tank to full and I mean full ,when I park up I get a drip drip drip and it stops after I've used some of the fuel, when you fill yours do you max the tank out if you do it might be whats wrong.
Hi Yes I do fill it to the top whenever I fill up but this has only just recently started happening. It's now half a tank and it still leaks.
 
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