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Old 12-18-2006, 11:39 PM   #1
Scooby Newbie
Member#: 135259
Join Date: Dec 2006
Location: WNY
1995 Legend

Legacy Legacy AWD Gas tank leaks! How to change ???

I am intersted in knowing if anyone out there has changed a fuel tank in the 1995 Legacy AWD?
I have a serious leak in mine (read Rust - I live inthe RUST BELT) and it needs to come out.
I have the new tank, but it looks like a bear to change.
It appears the car was built around the gas tank.
The tank hangs over both sides of the rear end and drive shaft.
The cradle for the rear suspension forms a cage behind the tank, and the cross member and sway bar make it a pretty impermeable cage to get the dang thing out.
I am seriously considering cutting the floor out, as it looks easier than taking the whole rear suspension out. (not to mention disturbing the all the fuel and brake lines, emerg. brake cables, hardware, etc. in the process.)
I just don't know if the tank can come out through the top. (width of the Unit body etc. )

Anyone out there replaced one?? Any suggestions?
I would appreciate any suggestions for shortcuts or helpful hints on what to / not do to make this easier, cuz it doesn't seem like it will be fun..
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Old 12-22-2006, 10:52 PM   #2
Dan Cech
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Member#: 67154
Join Date: Jul 2004
Chapter/Region: Tri-State
Location: Central NY
2007 Audi RS4


The FSM has the complete procedure, but basically it comes down to removing the rear section of your exhaust, the rear diff, axles and crossmember, and disconnecting all the hoses.

I would definitely not recommend cutting anywhere around there, as you'd destroy the structural integrity of the car, not to mention cutting + gasoline = bad times.
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Old 12-24-2006, 12:09 AM   #3
Scooby Guru
Member#: 88618
Join Date: Jun 2005
Chapter/Region: SCIC
Location: New Zealand
1994 Legacy
"The Silver Slug"


The only way that sucker is going to come off is down. Like Dan said, most of the rearend has to be removed, which will be a lot less of a hassle than cutting the floor.
It's just one of the bitch things that you have to do properly.
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Old 12-27-2006, 06:57 AM   #4
Scooby Specialist
Member#: 89385
Join Date: Jun 2005
Location: Loading...
many most all


It's been a while, but I thought it was easy.

I did not have to take the axles off the diff.

I lowered the diff with the axles still attached, and rocked the tank out.

Four boltz for the axle, few more for the shield, maybe six or eight (I forgot) for the diff...hoses and wire connections..remove exhaust.

For a first timer....I'd say four hours at the most.
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Old 12-27-2006, 01:54 PM   #5
Scooby Guru
Member#: 4021
Join Date: Feb 2001
Chapter/Region: NESIC
Location: Natick, MA USA
1999 Legacy GT Ltd
Quick Silver Metallic


Another suggestion would be to perform this procedure when you have little or no gasoline in left the gas tank. If you figure (guessing) that gasonline (in liquid form) weighs roughly 50 to 60 pounds for each gallon, then a half tank of gas might mean, like, 400 pounds.
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Old 12-27-2006, 02:10 PM   #6
Scooby Newbie
Member#: 43728
Join Date: Sep 2003
Chapter/Region: RMIC
Location: Utah!
2007 328iT


Originally Posted by Jonathan View Post
Another suggestion would be to perform this procedure when you have little or no gasoline in left the gas tank. If you figure (guessing) that gasonline (in liquid form) weighs roughly 50 to 60 pounds for each gallon, then a half tank of gas might mean, like, 400 pounds.
Thankfully gasoline isn't anywhere near that weight. It weighs roughly 6 pounds per gallon for a half tank weight of ~42 pounds.
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Old 12-27-2006, 09:18 PM   #7
Scooby Specialist
Member#: 11620
Join Date: Oct 2001
Location: Ontario
1997 GF4-STiV3 clone


It's a 4 hour job with a hoist and air tools. If you don't have those then it's going to be LONGER...
You will likely need new straps and hardware to hold the tank because the old ones will not come off in one piece.
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