The area where the filler neck goes into the tank and is leaking is part of the fuel tank isn't it? I looked in the RAVE and the parts breakout doesn't seem to show it separates in this area at a gasket.

 

I may be mistaken, but I thought there was a nationwide recall on this a few years ago. You stated you owned since 13k miles. Have you ever had it serviced at a dealer? I'm asking because if you did your VIN would have been registered and you would have received the recall notice.

 

Thanks for the lead Coors. Unfortunately, looks like that recall was only on a few years of D1's. I ended up siphoning some of the gas out of the tank; since I just filled it up 30 miles before this happened. I then used brake cleaner and cleaned/dried the area off and tried to weld the two pieces together with my soldering iron. After that I took some plastic and melted it onto the seam to beef it up some. Then for good measure scuffed it up with sand paper and put JB weld over the area.

Attempt at rewelding the factory seam:


Adding some more plastic on top with the soldering iron and a plastic hangar:


Seal it up with JB Weld:


I'm hoping this works. If not I'll just go buy a new one. Just a bit short on $$$ at the moment. Just took it off jackstands after replacing MAF, front diff, resealing rear diff, put on new headlight adjusters, and replacing the front oil seal. Starting to think this thing likes to be broken.

 

If it doesn't work, call Paul Grant He should have a used one.

 

its actually a semi-common place to leak. if you have an evap code this could be the source.

 

In case anyone comes across this, it did not work at all. Tried multiple times to JB weld more and it doesn't last but a few days. Ended up replacing the tank.