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Just an summary update on my fuel system issues, in case anybody cares.
My rear tank had sprung a leak and in the process of trying to get the gas out in order to patch it or drop it, it became apparent some crossfilling was going on. I could never get the damn thing dry, hence any attempts at patching were futile!
So at Bill's suggestion here, I decided the easiest and cheapest solution was to replace to dual selector reservoir with a single tank one. Nobody at the junkyard knew what I was talking about, so I had to go look under one of their old Broncos myself. Walah - there it was. I bought it for twenty bucks and installed it.
In doing so, the lines to and from the rear tank are left unconnected, which is what I wanted. I also disconnected the return fuel line on the passenger side of the truck going to the rear tank.
The end result is that gasoline is drawn only from the front tank. There must have been a little gas left in the rear tank, and I had to drive around for a few days to let it leak out and dry up. Finally it's no longer leaking and no longer smells of gasoline.
In doing all this troubleshooting, I've concluded that the gasoline system design on these older Fords is flawed and prone to problems. I mean, there's a low pressure pump in each tank whose purpose is to push gas to the reservoir. The dash selector switch activates the pump. The gas goes to the reservoir where it sits as a little reserve so that the high pressure pump has some gas to deliver in case the low one isn't primed. So the high pressure canister pulls gas from the reservoir. Then sends it through the filter. And then finally it gets up to the fuel rail. Whew! SEems like a whole lot of parts to do a simple task.
Well, a lot of people posting on these forums have reported the same issues with crossfilling, tanks not working, unable to select between tanks, unable to get accurate readings, etc...
I hope my description helps, and also Bill ("subford") is 100% expert on this stuff so anyone with problems - definitely should talk to him!
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