When the in cab tank in my truck has fuel in it I get a strong smell of gas. Looking at the tank I see dirt accumulated around the sending unit and fuel line where it looks like a prior leak occurred. Looking at this do you think the leak is still present and vapors are attracting dirt? What would the fix for this be? Tank replacement or is there a less expensive fix? Thanks.

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If it were me i would start off by resealing everything on the top of the tank and go from there.

 

I would do the same, but as soon as I started to smell the fumes, I'd try to catch the leak so you know for sure where the leak is.

 

Removed, replaced and resealed the sending unit gasket. Also removed and resealed the fuel line. No more smell.

 

Many people that have an in-cab tank are unaware, because the following is hidden from view and is the usual cause of fuel vapors wafting inside the cab.

The short fuel filler neoprene hose is clamped to the filler neck and to the outlet on the tank. Over time, the hose tends to swell up, causing it to crack.

The ends of the hose where it's clamped also tends to crack with age. Replace the fuel filler hose, it's the same 1961/77 for all in-cab tanks and is available from Carpenter for $10.00.

While you had the sending unit out, did you check the float? The float is made from two pieces of copper soldered together.

Solder breaks down, gas seeps in, float slowly settles to the bottom of the tank. The float is the same: 1957/79 Passenger Cars/Trucks, 1961/79 Econoline & 1966/79 Bronco.

Available from Ford (COAZ-9292-B) and from Carpenter ans etc..