2003 Gas Tank Failed - Replacement Options in 2025?

[mattdzu]

Hello all!

I have a 2003 TJ which has failed at the white/yellow plastic piece which connects the filler neck to the gas tank. If I go on any inclines; I can leak a substantial amount of gas so this is prohibiting use of my Jeep for Jeeping! As you can surmise, this is a grave problem.

In searching for options, it looks like Jeep doesn't have any stock of these gas tanks, nobody makes a normal aftermarket solution, and the used prices of these are exceedingly expensive in my local area. I had even inquired about a used one parting out on Craigslist and the individual broke it in the same spot trying to remove the tank.

I live in an area which requires emissions testing so I can't just do away with the EVAP system.

Options:
1. MTS makes a new polyethylene 97-02 tank ($600) - could I even make this work?
2. Barnes 4WD 13 gal. stretch tank ($800) - looks like I'd need to acquire 05-06 style fuel pump as well.
3. Motobilt Aluminum 14.5 gal. stretch tank ($800) - looks like I'd need to acquire 05-06 style fuel pump as well.
4. GenRight 24.5 gal. tank ($1,800) - maybe fits 03-04 style fuel pump but requires a 1" body lift.
5. Local Used ($800)

Is there any other options that I am not considering? Have others been able to get pre-03 tanks to work on 03-04 while retaining EVAP features?

Thanks in advance for any help y'all can provide.

Cheers

 

[JMT]

Hello all!

I have a 2003 TJ which has failed at the white/yellow plastic piece which connects the filler neck to the gas tank. If I go on any inclines; I can leak a substantial amount of gas so this is prohibiting use of my Jeep for Jeeping! As you can surmise, this is a grave problem.

In searching for options, it looks like Jeep doesn't have any stock of these gas tanks, nobody makes a normal aftermarket solution, and the used prices of these are exceedingly expensive in my local area. I had even inquired about a used one parting out on Craigslist and the individual broke it in the same spot trying to remove the tank.

I live in an area which requires emissions testing so I can't just do away with the EVAP system.

Options:
1. MTS makes a new polyethylene 97-02 tank ($600) - could I even make this work?
2. Barnes 4WD 13 gal. stretch tank ($800) - looks like I'd need to acquire 05-06 style fuel pump as well.
3. Motobilt Aluminum 14.5 gal. stretch tank ($800) - looks like I'd need to acquire 05-06 style fuel pump as well.
4. GenRight 24.5 gal. tank ($1,800) - maybe fits 03-04 style fuel pump but requires a 1" body lift.
5. Local Used ($800)

Is there any other options that I am not considering? Have others been able to get pre-03 tanks to work on 03-04 while retaining EVAP features?

Thanks in advance for any help y'all can provide.

Cheers

View attachment 600756

I occasionally see a stock tank for sale on Marketplace. Usually way less than $800

You could call MTS about compatibility.

Genright has several, Motobilt, Barnes, can’t recall if there are others. Might check TMR Customs.

 

[Lou]

I’ve got an 03 tank for sale out of Southern California. Where are you located?

 

[Username]

I used a jb weld plastic epoxy on a less severe crack on mine, it's been fine for about a year. When I get home later today, I can see which epoxy I used. It's worth a try before replacing the tank.

EDIT: This is the stuff I used, https://www.jbweld.com/product/plas...wDvj_7x-AbTdiOXS4whiL5QZWf3s9s-Y-bnZEPgKaV0qn

 

[TheBoogieman]

Salvage yards and rusted part-out Jeeps are everywhere. You might snag one cheap like this ($50).

https://www.facebook.com/marketplace/item/1581261752588827/?ref=search&referral_code=null&referral_story_type=post&tracking=browse_serp:5cbdc688-926d-4795-bdc6-2ba10aa9b8af

 

[WestCoastDan]

I would be concerned about replacing a failed, 22 year old tank with another 22 year old tank.

 

[twistedlv]

Hello all!

I have a 2003 TJ which has failed at the white/yellow plastic piece which connects the filler neck to the gas tank. If I go on any inclines; I can leak a substantial amount of gas so this is prohibiting use of my Jeep for Jeeping! As you can surmise, this is a grave problem.

In searching for options, it looks like Jeep doesn't have any stock of these gas tanks, nobody makes a normal aftermarket solution, and the used prices of these are exceedingly expensive in my local area. I had even inquired about a used one parting out on Craigslist and the individual broke it in the same spot trying to remove the tank.

I live in an area which requires emissions testing so I can't just do away with the EVAP system.

Options:
1. MTS makes a new polyethylene 97-02 tank ($600) - could I even make this work?
2. Barnes 4WD 13 gal. stretch tank ($800) - looks like I'd need to acquire 05-06 style fuel pump as well.
3. Motobilt Aluminum 14.5 gal. stretch tank ($800) - looks like I'd need to acquire 05-06 style fuel pump as well.
4. GenRight 24.5 gal. tank ($1,800) - maybe fits 03-04 style fuel pump but requires a 1" body lift.
5. Local Used ($800)

Is there any other options that I am not considering? Have others been able to get pre-03 tanks to work on 03-04 while retaining EVAP features?

Thanks in advance for any help y'all can provide.

Cheers

View attachment 600756

Mine failed just like that. I went with your option 4, and could not be happier. The thing is a work of art.
I already had a body lift.

 

[Steel City 06]

Do the Genright tank. Aluminum skid if you can afford it. (I have steel.)

You might be able to get away with less body lift if you're careful about where you route your vent hoses. Looking at mine, I really can't figure out what would interfere.

Genright tanks should fit any fuel pump. Note that the PSI changed between 2004 and 2005, so if you install an 05-06 pump, you may need to significantly cut back fuel in your tune.

 

[Steel City 06]

If money is tight, car-part.com is a good place to look for used tanks. There are also junkyards that exclusively part out jeeps (search Google)