Question: My 2004 Chevrolet SSR has the LS-1 (5.3-liter) V-8. The truck runs great and has no performance problems, but there is a big issue I'd like to solve without having to get a loan from the bank. This vehicle has a plastic fuel tank, but the filler hose is rubber, going into a metal sleeve at the tank. This sleeve is supposed to be tight, but it's loose, and I'm trying to find a sealant I can apply around the sleeve to fix the seal. Almost all the sealants in the automotive stores will not work when exposed to gasoline. A new fuel tank will cost well over $525, not including removal of the old tank and installation of the new one. Do you know of any sealant or any work that can solve this leaking problem? When I fill the tank, the fuel doesn't just leak out, it pours out. This isn't something small.
| truck Trend Garage 2004 Chevrolet SSR front View
Answer: Without having your specific fuel tank in front of me to inspect, I can only guess on its exact structure, but I would imagine it's cracked where the filler hose fitting is mounted to the shell. You might want to stop by a Chevy dealer and look at the parts diagram to be sure there isn't a seal that can be replaced and/or secured. You may also get a better look by dropping the tank. If you or the guys in the service department can confirm the tank is cracked, get it replaced. While an epoxy like J-B Weld, if applied correctly on completely clean and dry surfaces, can be resistant to gasoline and other petroleum-based products, the body flex applied to the fix by the attached filler hose will probably crack the epoxy. So because this is such a safety-critical component, I can only recommend spending the money and replacing the fuel tank.
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