1998 ford zx2, Fuel leakage when full

[Mlevan78]

Just looking for some input on an issue here.
I have a 1998 Escort zx2
It has been leaking fuel when the tank is full, usually leaks roughly one gallon prolly a little less.
i have had the gasket replaced where the fuel line goes into the tank.
it seems like the leak is coming from the top of the tank, and no one seems to be able to find it exactly.
Any input would be great so i can pass the suggestions along to a mechanic.

[zx2guy]

short of seeing it for my self its hard to imagine it. there are limited places it can come from... ive always been curious so i would rather check something out myself then get a mechanic to tell me everything is ok. it could be coming from a line, fitting,the pump, the tank its self might have a hole. the filler neck might be leaking at the tank. the possibilies are rather endless. if i were you, ild take the tank down (either have a mechanic do it or you... just remember to have the tank close to empty or pump out the gas... otherwise you will have a hell of a time.) gas ussually leaves some kind of mark, similar to when you get oil on your car. if there is no visable damage (rusted holes pierced marks, "rubbed" holes) then ild take it to a mechanic.you can also eliminate certain variables by asking questions. like " when does it leak?," "does it spray or make a hissing sound?",< when its running, is there a side of the tank where it drips?

[Mlevan78]

it seems to only leak under the following conditions;
* full tank
* driven for atleast 7-10 miles (then sits for atleast 2 hours)
* sitting idle for 20-30 minutes

and only leaks for about the first gallon of fuel consumed, i get 22mpg and after it has been driven 22 miles it doesnt leak.(this is city)

there does not seem to be any holes in the tank itself
after the gasket (gold color style washer) was replaced it seems to leak in less of a volume then before, but non the less it leaks.

the dealer is stumped.

it only leaks from the rear driver side of the tank (you can see where the fuel runs down from the top of the tank)

Anyone else here ever have this issue or hear about it before??

[zx2guy]

can you take the tank down to see exactly? ild hate to say it is this or is that specifically. going over things it can be in my head and it doesnt add up. if it were a pressurized line the thing would leak continually. i can only think of a hole in something. did the dealer show you the tank? if he didnt take it to a local garage (one of those small town guys that wont mind you in the shop area, dealers are pricks when you ask to see what exactly is going on. have them take it down and physically show you... and while you are looking at the tank ask to see under the car... granted when you drop anything with fuel there is bound to be minor leakage. but again you are looking for those streaks. then go from there.

[darktsx]

I had the exact same problem with a 98 zx2 .. I'm sorry that I don't remember exactly where the leak was. The dealer wanted $800 from me to completely replace the tank but a mechanic plugged it up for around $100.