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I have a strange problem with my 1994 F150 Flareside. As near as I can figure out, the front gas tank leaks, but only sometimes and I never see any gas leaking out when its parked.
When it does "leak", there is a strong smell of gasoline outside the front filler door and a tank only lasts about a week. This doesn't happen on a regular basis, though. It has happened four times since June. I never have any problems when I run on the rear tank.
Any ideas as to what is happening?
It's possible you have a bad tank selector valve so it ends up drawing from one tank but returning to the other, thereby overfilling it. Ford had a recall for something like that which included mine (a '90) but I don't know what years were involved or the exact situation. Other things to check - a damaged vent tube inside the filler neck or a leaking line where it goes into the top of the tank.
Have you noticed if the fuel from the rear tank is going to the front tank? When you switch to the rear tank is it empty?? Is there a build up of pressure when you open the front gas cap. I didn't see any recalls for your truck at www.alldata.com though. I think for this problem on the 90 to 93 models they added a cross flow check value to the fuel lines.