Other Fuel System Tank Assembly Problems of Chevrolet Express 3500

Have a 2012 Chevrolet cut away van for a school bus use. Started leaking gasoline out of the pressure side line on the furl module. Had to have towed to chevy dealer for repairs. They had to remove fuel tank to make repairs . They replaced fuel module in the tank. The cost of repairs was 1166. 41$.

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The van is a 2012 cut away school bus. On 1-20-2018 developed a gasoline leak on the vent side of the fuel module on top of the fuel tank. Took to chevy dealer for repairs. They replaced the fuel module inthe tank. They had to remove the tank to perform repairs. At a cost of 1188. 39$.

Fuel tank corrodes and leaks fuel on the highway.

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When the vehicle fuel tank is filled, gas fumes are detected and some fuel can be seen on the bottom of the tank (a few drops of fuel). As the tank contents lower the smell and leak goes away. An access hole on the side of the van reveals that the tank has a small leak where the plastic fill neck was bonded to the tank. The steel fill neck and rubber connection look fine. This is a conversion van w/o a left hand door. This vehicle was bought from a southern climaate area and is only recently been brought to a northern climate so corrosion is not suspected. Since I see no recall or many complaints, I am looking to repair or replace the tank. Currently looking for a seal material that could be applied to the leak and that works on polyurethane and resists fuel. Have not found one. The vehicle is well out of warranty but this does seem to present a safety issue. Short term solution is to not fill the tank.

See all problems of the 2003 Chevrolet Express 3500 🔎.