Fuel Tank Replacement 400DA

D

douglee25

Well-Known Member
Jan 13, 2008
4,761
Dallas, TX
Boat Info
Cruisers 3575
Engines
Twin 7.4l
I had a broker contact me the other day regarding a clean '99 400DA that apparently has a fuel leak. They don't have many details on the leak itself because it's bank owned.

Anyway, what is involved with the worse case scenario for fuel tank replacement on a 400?

Doug
 
WOW, that's some task, Doug. From what I recall on similar models (I never saw ER of 400, but I'm sure it's similar to 410/420DA) I would think that an engine (whatever side the tank is) will have to be pulled to allow enough room for the tank to come out. I'm not positive, just giving my thoughts based on the amount of room in there.

Apparently, it's critical to kno 100% where the leak is. You maybe able to hire a professionals to weld the tank without taking it out.

I hope the leak is someplace else and repair is minimal.

Good luck,
Alex.
 
That might be the first bad tank I've heard of in a 400DA. The starboard tank is larger, but there's a secondary access hatch next to the main hatch that might offer some valuable clearance. Just by looking, it appears that the tanks might be able to be slid aft and out, but I don't know if they would clear the engines. In the way of the stbd tank moving into the ER is at LEAST: aft head VG, generator, vertical support and horizontal support for the access hatches. In the way of the port tank are the batteries, a vertical support and the holding tank.
 
So basically one or two engines have to come out in order to access the engines (the big cost anyway)?

Doug
 
They said startboard fuel tank. They knew very little details on the boat. Just that it's bank owned and I could probably get it for a decent price if it was something I was interested in. The bank has refused to sink any money into the boat to diagnosed. It's one of those 'as is/where is' sales.

Doug
 
Are you sure its even the tank and not a supply line or fitting leaking somewhere? I have seen them cut open the side of a 44 Express Bridge to get a fuel tank out before, apparently it was cheaper than pulling the deck and the engine.
 
True. I guess it could be cut out fairly easily. Getting it back in would be fun!

Doug
 
Might be worth hiring someone to check it out and report back only to you.
 
That is a big job on a 400/410DA. The cockpit and cockpit deck has to come out and at least the engine nearest the tank must be removed.

I've only heard of Sea Ray tanks leaking in older boats or in newer boats that have been submerged. The tanks are aluminum and are no where near bilge water. Be very careful with this one...............
 
The port tank on my 390DA had to be replaced before I bought it due to a leak. Port engine had to come out and a lot of other stuff...batteries, etc. Big job and big labor $$$$$. Mine was done on warranty / previous owner thankfully. Good luck.
 
A friend of mine with a 2007 40 Sundancer (diesel) developed a fuel leak in his starboard fuel tank, Sea Ray and myself could not find the leak, all we knew was that it had to be near the top of the tank as it only leaked when the tank was more then 3/4 full. There was some heated conversations with Sea Ray as to who was going to pick up the bill, (about $20K!!).... Sea Ray finally agreed to pick up most of the bill (all but about $4K), the work was fairly extensive , they had to remove the Starboard engine as well as the generator, there was some bulkhead area that had to be removed that required some fiberglass work to reassemble. The work was done by Marine Max in Lindenhurst LI NY.
 
douglee25 said:
I had a broker contact me the other day regarding a clean '99 400DA that apparently has a fuel leak. They don't have many details on the leak itself because it's bank owned.

Anyway, what is involved with the worse case scenario for fuel tank replacement on a 400?

Doug
Click to expand...

What ever happened with this? I'm in exact same scenario, except its a 1997 400DA, starboard tank has a leak. Bank owned, and boat really clean otherwise with healthy CATs.
 
The good new with this is that the tanks can be reproduced. They are supplied by Florida Marine Tanks and they still have the original construction drawings. But, as I said earlier in this thread, the boat has to be torn apart to remove the old tank and replace it with a new one. No…it cannot be repaired in the boat because the cause of the leak is almost certainly the result of water in thew fuel and corrosion on the bottom of the tank. With a haul out, lay days in the boat yard, crane or other suitable lifting services, tank cost, removal of the cockpit seating, the cockpit deck and the engine/transmission, 2 men for several days, I see the starboard tank replacement a project where there wouldn't be munch change left from a $10,000 bill.

Then, have you considered that whatever caused the corrosion in one tank probably affected the other one as well?
 
So I've asked an adjusted price of $10k, so if thats the repair cost then I'd be ok with it, and save it for winter. The previous owner ran a fuel line for the generator to port tank. As for what caused the corrosion we don't know yet, but there is new fresh water plumbing in the bildge, I wonder if that is related, and if there's plumbing running along that tank. Only water on starboard is the aft bathroom. Maybe there was a leak there. With the $10k adjustment it'd be $60k under BUC value, so I still have a decent buffer. I'll update this if and when there are any.
 
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