krw

Well, it 'appears' to have been an intermittantly shorting fuel pump. I replaced it and have only test driven for about 50 miles on road and a mile off but so far, so good. I ran two extra wires from the dash to the top of the tank just in case I need them later on. I also discovered a rotted body mount while running the wires. TG for welders and angle iron. Thanks guys for the suggestions and I am keeping my fingers crossed. BTW, the new pump had the filter rotated 90 degrees. No big deal - just compare with the old one.

Grenade - Please do so when you get a chance. I would appreciate it. Slartibartfast - I have bolts soaking in powerblast (a bit rusty). Hopefully I can get them out intact. A short in the tank, especially an intermittant one is a a bit frightening. Thanks.

1992 Pathy. The fuel pump fuse blows frequently - usually when hitting a small bump. Obviously there is a short in the wiring. I have followed the harness from the tank (through the access door) to the A post and found no problems. My larger issue is that I do not know the color code of the wiring and the FSM does not seem to show it. Has anyone solved this problem? What is the wiring color code? Could the short possibly be inside the tank? (That sounds dangerous to me). Thanks.

Thanks for all of the info Overland. After contacting Courtesy Parts I found out that their tank is also only 15 gallons. That's just unacceptable, particularly for their price. I guess I will go the junk yard route. (If you have time and ambition) could you tell me of any issues you ran into in the actual exchange process. This will be my first on a PF, but not my first tank. I like to be well prepared when I can. Maybe I will photograph the process and post a tutorial. I've done that for an alternator swap on my wife's Passat. (You have to jack up the engine!). That post was well received. Karl

Hi guys, It's time to replace the gas tank on the '92(leaking at the seam). The problem is I have only been able to find 15 gallon replacements and I know that I have put 18-19 gallons in the existing one. I am guessing that the original is 21 gallons or so, although the FSM doesn't say. Does anyone know where to find a 21 +- gallon tank? Even Rock auto doesn't seem to have any. I'd hate to cut capacity by 25%. Thanks in advance.

Boy, do those photos look familiar. I did my passenger side two years ago and DS a last year. I also extended forward to the firewall using 3" x 5" angle iron. Solid as a rock now and you can jack it up from anywhere, but the body is going. No longer pretty but good enough for off road and daily local driving. Almost time to get "Historical" designation. The insurance will be cheaper.

I know this is two months after the fact but might be useful to someone in the future. I had the flex hose to the slave cylinder get spongy during an off road session. A pin hole appeared on the way home.(This was a hard to find part BTW. Don't know why, the truck is *only* 18 years old). The easy way to bleed the system is with a vacuum pump at the slave cylinder bleeder. You can buy a cheap hand operated pump at Harbor Freight and similar places.

Mesage received and Hello!

Wheelman, Do your homework (like you've already begun). My experience with high current alternators is on emergency vehicles. Many, if not most, of them provide very LITTLE current at engine idle. You need to turn at least 1200 engine RPMs to make even 100 amps. They also generate more heat than 60 - 80 amp units. I don't really know if versions for smaller vehicles have the same issues. Of course you can overcome both problems. The first with awareness and the second with air flow. Good luck.