38 Zephyr gas tank removal ?

[3738]

Friend has a 38 Zephyr Convertible Sedan he just bought.

Today he called me to tell me it is leaking gas somewhere at the gas tank. Did not have time to do anything other than drain the tank and see a couple sections of fuel hoses with splits in them (leading to filters), which will need to be replaced. Fuel was also coming down the drivers side flange of the tank, which could be a leak at the flange or the filler neck above.

I'll be taking a floor jack and stands next week for a closer look, but before I go, I am wondering if the connection of the filler neck and placement of the tank flanges on top of the frame rails are much different than my 38 Ford Coupe ?

Does the filler neck connect to the tank with a rubber sleeve and clamps, or some other system ?

IIRC, can I remove the bolts holding the tank, move it all the way towards the drivers side, drop the passenger side down and remove the tank like in my 38 Ford Coupe ?

Here is a picture I took of that series of leaking hoses connected to a series of fuel filters and on the right side what looks like an electric fuel pump that someone previously installed ? Probably not stock, as the hose clamps are modern ?

Anyone have experience advice on removing this gas tank ?

 

[Vic Piano]

None of the fuel line "add-ons" are stock. The '38 & '39 Zephyrs (and possibly earlier) have the fuel tank filler neck crimped and/or pressed onto the flange at the tank (please forgive what might be the wrong terminology) they are prone to leaking at that spot on the filler neck and it gives the impression that gas is actually leaking from the tank, not the filler. I have this problem on our '39 LZ and a friend of mine has the same problem with his '38. I took a large diameter rubber hose, cut it lengthwise, wrapped it around the filler neck as close to the tank as I could and secured it with hose clamps. That works as long as you don't "top off" the gas tank. Obviously not a permanent fix.

 

[3738]

Vic,

Can I remove the tank from this 38 Zephyr, (like I did on my 38 Coupe), without having to lift the body ?

 

[Vic Piano]

I assume your '38 Coupe is a Ford because the Zephyr is a unit-body construction so you can't easily lift the body from the frame. I did not remove the gas tank from our '39 LZ so I can't give you any "tips" on the best and/or easiest way to remove it.

 

[Ken/Alabama]

The filler neck screws in the tank and is sealed with a lead washer. When I removed mine I put a pipe wrench on it and whacked it with a hammer to jar it loose. There is a good chance the leak is coming from the lead washer. The tank is impossible to remove with out first removing the filler pipe. If you need a picture of the filler neck I can post one here, I have mine out of my 39 Zephyr.

 

[Vic Piano]

Ken, can you post a photo of the lead washer? I'd like to see how that is set up. also, did you remove the fender before you took the filler pipe off? Thanks. Vic

 

[3738]

Ken,

Yes, please post some pics...

 

[jimalabam]

Hi Ken, Good to see your post, what is the latest with your Z car? Best regards, Jim Langley...

 

[Ken/Alabama]

Here are some pics of the filler pipe and lead washer. My fender was removed but if you can get the pipe unscrewed from the tank I dont think you would have to remove the fender. The fender brace or spash pan might need to be moved for better access. Mac has the lead washers available.

 

[Vic Piano]

Thanks Ken, I'll have to get the lead washer and see if I can fix our '39. Vic

 

[Ken/Alabama]

The holes in the threaded sleeve are for using a spanner wrench . I have a spanner wrench that I modified a little that will work for this but it can be a real knuckle buster if your not carefull, I used a pipe wrench on mine cause the could get a better grip than the spanner without slipping. I will use the spanner to reinstall it.

 

[Ken/Alabama]

Hi Ken, Good to see your post, what is the latest with your Z car? Best regards, Jim Langley...

Hi Jim, The body in back on the chassis. Havent had much time lately to do anything to the Zephyr. Just got home from a week at the Gulf Coast. Will start pulling the engine out of my 40 Coupe in the morning, I need to re-ring it and it has a broken valve spring also. Dawsonville is just around the corner you know.

 

[3738]

Due to the shape of the filler neck, it appears that I would need to drop the tank in order to unscrew the filler pipe ?

 

[Ken/Alabama]

Believe me, You cant drop the tank without first unscrewing the filler pipe. Remove the rubber grommet in the fender around the filler pipe and it will give you more wiggle room.

 

[3738]

Ken,

Sounds like I'll need to remove the grommet, unbolt the tank, shove the tank as far as possible towards the passenger side and then maybe have enough room to unscrew the filler pipe ?

This is the very nice 38 Zephyr out of the Dingman Auction, so I don't want to remove the fender skirt and fender unless absolutely necessary, which is why I'm asking about the removal procedures before I start any more work.

 

[3738]

Worked on my friends 38 Zephyr today. Removed the splash shield inside the fender. Discovered the fuel neck doesn't thread into the tank, but a collar around the filler neck that you tighten with a spanner wrench (or carefully with a pipe wrench) actually turns while you hold the filler neck in the center of the hole in the fender. I was able to get almost a full 360 degrees of tightening/turning on that collar. Here's hoping that sealed the leak.

Removed the Zephyr logo dead battery, (looks like it may have an Optima inside a Ford/Zephyr case), replaced it with a new plain 6 volt battery. Ran a length of gas line to a gas can, primed the carb and got the V12 running enough to confirm no mechanical issues with the engine.

Removed a series of aftermarket fuel filters, electric fuel pump to replace all the split hoses and although not stock, reinstalled everything to see if it runs well with what someone added previously. Didn't fill the gas tank to full yet, but the neck seal did not leak while pouring in the few gallons I had on hand into it. I'll be back at it tomorrow sorting out a few other minor loose ends.

 

[Vic Piano]

That sure is a beauty. Can you tell me what brand the double sided white walls are and if they are 700x16's, thanks. Vic

 

[3738]

Vic,

These are BFG Silvertown 700 X 16, whitewalls on one side only

 

[Vic Piano]

I guess I didn't look close enough at the first photo... that plus I've been trying to find double sided white walls in the 700x16 size to put on our Zephyr.

 

[TonyM]

Man, that car is sharp. Good luck with the fix.

TM