Aspire: Fuel tank pump seal still leaks

[23Turbo]

I've searched around here and the aspire forums and found nothing, so figured I'd post up. I have a '94 Aspire 3dr. A while back I had pulled the fuel pump assembly out of the tank due to a bad sending unit. After putting everything back together, I'd get fuel leakage coming out of the top whenever I filled up. I purchased a new fuel pump lock ring kit (rubber seal w/ new screws). When I pulled the pump assembly out, I made sure I cleaned the surface of the tank seal really good, and cleaned up the fuel pump assembly side of the seal as well. Installed new seal, tightened down screws really good. Went to fill up yesterday, damn tank still leaks. I do not have a haynes manual handy, but is there some type of adhesive or sealant that is supposed to be used on the sealing surfaces? When I had everything apart, I noticed a few of the screw holes are exposed through the tank, others are not. Can fuel be seeping out through there??? Any ideas?? Thanks.

[batstiva]

Okay, just re-checked my Haynes, just to be sure. No adhesive is called for. And I would think that would be a bad idea anyway, because the next time you have to get in there would be a bear. Also went out and looked at my fuel tank/sending unit set up. Mine's a carbed festiva, but I don't think there's a difference as far as removal/installation is concerned. None of my screw holes actually go all the way into the tank. Sounds like whoever had the car before you used some too long screws. Guess you could seal the holes with rtv or something, but then you would not want to screw back into them. You may end up having to look at a replacement tank.

[23Turbo]

Thanks for the response. Really don't want to look into a tank at the moment, I'll think of something. For the meantime I'll be ok, just won't be filling up anymore. Good thing these cars get such great gas mileage

[batstiva]

I ran mine for a year, never filling it above 1/2 tank, because the seams on my tank where the two halves came together was leaking. And all the used tanks I looked at were worse off than mine.