Fuel tank delamination - Diesel Forum - TheDieselStop.com
E-Series Vans Technical discussion of topics related to vans powered by any of the Navistar engines. This covers a broad number of years, but there isn't enough demand to split it any further.

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post #1 of 25 (permalink) Old 01-09-2014, 06:44 PM Thread Starter
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Fuel tank delamination

Finally ran the van low enough (LOW FUEL LIGHT IS ON) to do the fuel/water filter. I was "lucky" enough to find little flakes in the filter housing.
My fuel pump has been noisy since I got her van, probably full of pieces
Found the article from Heavyhitter on his solutions and other folks problems with the OEM tanks.
Did anyone check out whether the tank from the 2011 would fit?
If that tank is plastic will it hold up to the diesel fuel?
I looked at the aluminum tank on Ujoint's site $1399 is a lot for a tank, but then it would be a one time fix.
This probably why the motor has gone into the shakes and lost power every once in a while.
So I am looking at options.
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Chuck
2005 E350 6.0 Passenger Van
Blue spring fuel regulator upgrade, FICM Atlas 40 Tune, Fuel tank recoat, Scan Gauge II, Shell Rotella T6 5w-40w
2010 Porsche Cayman S (mine)
2008 BMW 535xi wagon (hers)
2003 Porsche Boxster S 6 spd (hers)
2006 BMW Z4 M Coupe Sold
1996 Ford E150 Grand Chateau Van 198k mi SOLD!!!!
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post #2 of 25 (permalink) Old 01-09-2014, 10:41 PM
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Sorry to hear this,
Check this recent thread if you haven't seen it already. I'm sure there are others, I just remember this one.

http://www.thedieselstop.com/forums/...n-mods-391066/

Hope you get it sorted soon.

1996 E350 XLT E | 280K and gone
2003 E350 XLT club 190k
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post #3 of 25 (permalink) Old 01-10-2014, 09:57 AM
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There is a TSB or several out there, maybe the Dealer will foot the bill,

Van E350 TBS Fuel Tanks from Ford Info:
2000 FORD E350 Recall ID from NHTSA: 01V114000
Auto Recall Date: 20010405
Vehicle Component: FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY
Estimated Vehicles Affected: 151000
2000 FORD E350 Defect Summary:
VEHICLE DESCRIPTION: ON CERTAIN VANS WITH AMBULANCE PREP PACKAGES OR OTHER SEVERE-DUTY APPLICATIONS INVOLVING OPERATION AT OR NEAR THE GROSS VEHICLE WEIGHT WITH FREQUENT TWISTING OF THE VEHICLE BODY, SUCH AS OFF-ROAD, ROUGH ROAD OR SPEED BUMP EVENTS, THE 35 GALLON MID-SHIP FUEL TANK COULD DEVELOP A CRACK WHERE IT CONTACTS THE FRAME CROSS MEMBER. IF THE FUEL TANK CRACKS, FUEL LEAKAGE COULD OCCUR.
Defect Consequence:
FUEL LEAKAGE IN THE PRESENCE OF AN IGNITION SOURCE COULD RESULT IN A FIRE.
Remedy:
DEALERS WILL INSPECT THE FUEL TANK AND, IF CRACKED, WILL REPLACE THE TANK. INSULATOR PADS WILL BE INSTALLED ON ALL VEHICLES TO REDUCE THE STRESS LEVELS IN THE FUEL TANK. OWNER NOTIFICATION BEGAN APRIL 19, 2001. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT FORD AT 1-800-392-3673.
Notes: FORD MOTOR COMPANY, 01S14

2000 FORD E350 Recall ID from NHTSA: 00V284000
Auto Recall Date: 20000921
Vehicle Component: EQUIPMENT:OTHER:LABELS
Estimated Vehicles Affected: 4500
2000 FORD E350 Defect Summary:
VEHICLE DESCRIPTION: BI-FUEL CNG PICKUP TRUCKS AND BI-FUEL CNG VANS, MODIFIED BY CFI CONTROL SYSTEMS, INC., FAIL TO CONFORM TO THE REQUIREMENTS OF FMVSS NO. 303, "FUEL SYSTEM INTEGRITY OF COMPRESSED NATURAL GAS VEHICLES." THE LABEL AFFIXED TO THE FUEL FILLER DOOR BY THE VEHICLE MODIFIER CONTAINS THE INSPECTION DATE AND EXPIRATION DATE OF THE CNG TANK. HOWEVER, IT DOES NOT CONTAIN THE STATEMENT "SEE INSTRUCTIONS ON THE FUEL CONTAINER FOR INSPECTION AND SERVICE LIFE."
Defect Consequence:
THESE VEHICLES DO NOT COMPLY WITH THE REQUIREMENTS.
Remedy:
OWNERS WILL BE PROVIDED A LABEL WITH THE REQUIRED STATEMENT, ALONG WITH INSTRUCTIONS FOR AFFIXING THE LABEL AT THE FUEL FILLER DOOR. OWNER NOTIFICATION BEGAN NOVEMBER 2, 2000. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT FORD AT 1-800-392-3673.
Notes: FORD MOTOR COMPANY, 00L07

2000 FORD E350 Recall ID from NHTSA: 00V115000
Auto Recall Date: 20000419
Vehicle Component: WHEELS:LUGS/NUTS/BOLTS
Estimated Vehicles Affected: 3300
2000 FORD E350 Defect Summary:
VEHICLE DESCRIPTION: CUTAWAYS AND STRIPPED CHASSIS WITH SINGLE REAR WHEELS. THE LUG NUTS CAN POTENTIALLY BOTTOM OUT ON A SHOULDER ON THE STUDS.
Defect Consequence:
IF THIS OCCURS, THERE CAN BE AN INADEQUATE CLAMP LOAD TO ATTACH THE WHEEL TO THE AXLE, RESULTING IN NOISE, DAMAGE TO THE WHEEL AND HUB, OR IN EXTREME CASES, LOSS OF A REAR WHEEL WHILE THE VEHICLE IS BEING DRIVEN.
Remedy:
DEALERS WILL REPLACE THE REAR WHEEL ATTACHING STUDS.
Notes: FORD MOTOR COMPANY, 00S08

2000 FORD E SERIES Recall ID from NHTSA: 03V094000
Auto Recall Date: 20030307
Vehicle Component: STRUCTURE
Estimated Vehicles Affected: 3674
2000 FORD E SERIES Defect Summary:
CERTAIN PICKUP TRUCK, VAN, AND MINI VAN CONVERSIONS EQUIPPED WITH SOUTHERN COMFORT BUILT RUNNING BOARDS THAT CONTAIN CERTAIN COURTESY LIGHTS MANUFACTURED BY AMERICAN TECHNOLOGY COMPONENTS, INC. THESE UNITS CONTAIN A COURTESY LIGHT OR LIGHTS THAT MIGHT OVERHEAT WHEN THE WIRE HARNESS IS EXPOSED TO EXCESSIVE MOISTURE AND ROAD SALT.
Defect Consequence:
THIS OVERHEATING CONDITION CAN CAUSE THE RUNNING BOARD TO MELT OR CAUSE A FIRE.
Remedy:
DEALERS WILL REPLACE THE WIRING HARNESS ON THESE RUNNING BOARDS. OWNER NOTIFICATION BEGAN MARCH 7, 2003. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT SOUTHERN COMFORT AT 1-800-745-6096.
Notes: SOUTHERN COMFORT CONVERSIONS,

2000 E350-Super Duty Ext. Mobile LivingRoom-7.3LPSD
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post #4 of 25 (permalink) Old 01-14-2014, 03:36 PM Thread Starter
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Dropped the tank out, bought the tool to unhook the QR fuel line fittings.
Plenty of crap floating around in the tank,
The two fuel vapor valves on top of the tank, how do they come off?
Do they just pull out or is there something to release to get them off?
I could fuscle muck them off, but I have the time to not F them up.
Thanks

Solved
Turn them1/4 turn counterclockwise and they come out
ate lunch and the brain was engaged again

Chuck
2005 E350 6.0 Passenger Van
Blue spring fuel regulator upgrade, FICM Atlas 40 Tune, Fuel tank recoat, Scan Gauge II, Shell Rotella T6 5w-40w
2010 Porsche Cayman S (mine)
2008 BMW 535xi wagon (hers)
2003 Porsche Boxster S 6 spd (hers)
2006 BMW Z4 M Coupe Sold
1996 Ford E150 Grand Chateau Van 198k mi SOLD!!!!

Last edited by 02chuck; 01-14-2014 at 04:20 PM. Reason: problem solved
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post #5 of 25 (permalink) Old 02-04-2014, 01:30 PM
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My 00 e350 suddenly died
Had it towed home since dealer was closed for the weekend
Changed fuel filter and found teeny tiny silver what looked like gold fish flakes in it
Researched it and guess what
Tank goal delam
Dropped it and the inlet screens secondary pickup screens lines to and including the fuel pump all clogged
Dealer says they never heard of this
100 for oem naked Bosch pump
300 aftermarket NiTrene new tank ordered
Cleaned out the two screens and pickup assembly and all lines
Another new fuel filter
Just waiting on the tank
Dealer says it would be 1800-2500 to replace all
Hope this didn't trash an injector(s)
Contacted FoMoCo hoping to get so e relief but they say this was a 03-07 issue only
BS - google it and read 20+ articles
In the end this will cost me 5000+ in lost wages on that van plus parts and my labor
So if you have any fish flakes lol in your filters = not good
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post #6 of 25 (permalink) Old 02-05-2014, 06:35 PM Thread Starter
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Completion of tank repair:
Had the tank cleaned out and recoated.
Reinstalled it, fueled the truck up and it started right up (no leaks).
For me many times I have the "Chuckie" factor F ing something simple up.
Took the truck down, fueled it up, added a dose of fuel additive.
It seems to run really good. the PHP Atlas tune up to the FICM seems to help in throttle response and get up and go.
Changed the oil to the Rotella T6, the NAPA oil filter cartridge drain would not come out, so I had a bit of a mess when I pulled it apart. Had a new OEM cartridge housing to put on.
Next up is the coolant and filter

Chuck
2005 E350 6.0 Passenger Van
Blue spring fuel regulator upgrade, FICM Atlas 40 Tune, Fuel tank recoat, Scan Gauge II, Shell Rotella T6 5w-40w
2010 Porsche Cayman S (mine)
2008 BMW 535xi wagon (hers)
2003 Porsche Boxster S 6 spd (hers)
2006 BMW Z4 M Coupe Sold
1996 Ford E150 Grand Chateau Van 198k mi SOLD!!!!
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post #7 of 25 (permalink) Old 02-05-2014, 11:31 PM
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I've prob said this before here, but when it happened to me, I only had my main tank boiled out for 2-300, not relined, and that's it. The block filter caught all the flakes (that I know of), but never had an issue with the pump or injectors (that I know of). It also had to run under these conditions 2 different times on its way to the shop to get fixed, shuddering, starving for fuel... this was some time ago, and had no need to spend thousands on repairs, as was mentioned above.

2001 E350 PSD, Deep Emerald Green, 3.55 LS, Premium package, dual alts, rear A/C. Quigley 4x4, Transfer Flow rear tank (27+26), handicap mods, custom interior, Reunel tire carrier w/ Hi-Lift, Sportsmobile nerf bars (black), Amsoil lubes and Dual-Gard bypass oil filter, Amsoil air filters, Eclipse/JL Audio sound system w/ Sirius & 192GB Pono player, J&J stainless grill, Reunel Stainless bumper, 12000# Warn winch, PIAA lights, RIP Kit w/ Fox shocks, Dick Cepek wheels, Michelin tires (265/75-16), Correctrack rear wheel spacers, Bushwhacker flares (painted), Velvet-Ride spring shackles, p/s filter, external trans and coolant filters, Autometer gauges(5), Optima Blue Tops, Airdog.
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post #8 of 25 (permalink) Old 02-07-2014, 09:02 AM Thread Starter
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We were lucky that the truck ran OK when I bought it , as I had a friend fly back to Arkansas to pick it up and drive it back to California. Once I get caught up with the PM it should be in good shape. I did not get any maintenance records so I am going through it to be sure it is in good shape.

Chuck
2005 E350 6.0 Passenger Van
Blue spring fuel regulator upgrade, FICM Atlas 40 Tune, Fuel tank recoat, Scan Gauge II, Shell Rotella T6 5w-40w
2010 Porsche Cayman S (mine)
2008 BMW 535xi wagon (hers)
2003 Porsche Boxster S 6 spd (hers)
2006 BMW Z4 M Coupe Sold
1996 Ford E150 Grand Chateau Van 198k mi SOLD!!!!
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post #9 of 25 (permalink) Old 02-19-2014, 07:22 PM
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Just a update on my Tank nightmare the new tank is delaminating as well flakes , flakes flakes .....

4x4 quigley 2001 e350 psd 3.55 posi front & rear/ insulated fully/ all power/ 4flex steel 6 way heated/rear removeable leather captain chairs / carbon fiber dash cover/ 2000watt rockford fosgate sound system system12 speakers/scmt/magna flow complete from turbo back/carbon fiber gauges auto meter trans,boost,exaust pre/isspro tack/crime stopper alarm remote start stop /towing package/
Custom Pro Built Trans steel planets tripple disc Red Eagle discs hardend input & drive drum /
W/A Intercooler... SIngle shot stage 2

2001 E350 4.10 all stock cargo 140k
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post #10 of 25 (permalink) Old 02-20-2014, 12:13 PM
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Tank delamination

What tank did you buy so we don't buy that brand
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post #11 of 25 (permalink) Old 02-22-2014, 03:22 PM
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For those of you who have experienced delamination, were you using fuel additives? I'd heard that "excessive" amounts of fuel additives - whatever that means, can contribute to delamination. I've haven't used them for the past four years in my vehicles with steel fuel tanks as a result of this rumor/speculation.

Here is one article alluding to additives and delamination:
Tank Delamination Solutions - 8-Lug Diesel Truck Magazine All Pages

Biodiesel is also strongly implicated in many of the delamination cases, but that isn't readily available to me anyway.

2003 E-350 14-passenger, 3.73, Quadvan 4x4, AIC, TransferFlow 46 gallon tank, DP tuner, bellowed up-pipes, DieHard Platinums, Hella Rallye 4000 driving lights, 17" Hakkapelliitas snow tires, 18" Continental ContiTrac summer tires, front receiver hitch
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post #12 of 25 (permalink) Old 02-23-2014, 09:42 AM
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Have to use them
Fuel gels here plus the cetane level is so low with all this bio mixed crap that the 7.3 loves the higher cetane
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post #13 of 25 (permalink) Old 02-25-2014, 04:15 PM
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Is this problem specific to certain years, or all E-series with steel tanks?

Mine: 04 F250 cc,4x4, 6.0, studs, Banks air in, thru, & out, Bulletproof "everything", stage 2 Powermax w/BatMo, headwork, stage 1 sticks, airdog, Mag hytec covers & pan, Trutracs, 4" lift on 35s, Custom tunes...
Hers: 99 E350 CW 15 pass, 7.3, 4" turbo back w/Corsa RSC, Infinity w/tunes by Jody 60tow, 60mtn, 80e, 80mtn, 100perf, 120race, 4" lift on 33s, 3rd & 4th rows removed perm, 38r coming, "who will get to the tranny first, me or the motor?"...
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post #14 of 25 (permalink) Old 02-26-2014, 09:43 AM
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All steel tanks from 1997 to 6/2007 f series, e series, cutaways, modified, ambulance with midship tank(s)
Ford only admits to the 03-07 failure too
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post #15 of 25 (permalink) Old 02-26-2014, 04:33 PM
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tank

Quote:
Originally Posted by blazerguy65 View Post
What tank did you buy so we don't buy that brand

Well My new tank was modded cut off and a piece of steel was welded in and painted by welder Im sure its the paint he put on it and not the protective coating so im just going to keep cleaning pre fuel pump filter and see if it stops , also my neighbor has a 2000 + chevy diesel and he has Heavy flakes in his filter as well so its not just Fords

4x4 quigley 2001 e350 psd 3.55 posi front & rear/ insulated fully/ all power/ 4flex steel 6 way heated/rear removeable leather captain chairs / carbon fiber dash cover/ 2000watt rockford fosgate sound system system12 speakers/scmt/magna flow complete from turbo back/carbon fiber gauges auto meter trans,boost,exaust pre/isspro tack/crime stopper alarm remote start stop /towing package/
Custom Pro Built Trans steel planets tripple disc Red Eagle discs hardend input & drive drum /
W/A Intercooler... SIngle shot stage 2

2001 E350 4.10 all stock cargo 140k
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