Hey, Last summer I had a gas leak in my '97 Legacy Outback. The very bottom of the fuel filler pipe had a pinhole leak which I covered with JB Weld, and it stopped leaking until a few days ago. I scraped off the old JB weld, sanded the pipe again, and then put new JB Weld on. After refilling my tank, the fuel filler pipe was no longer leaking.
However, once I parked in my driveway, I noticed a big puddle of gasoline under the center of my car. After opening the compartments in the back of the car, I saw that the fuel sending unit assembly was spraying gas (the fuel pump assembly on the other side, though rusted, is not leaking). The small metal tube coming out of the plate at a right angle had a pinhole leak. I used rubber fuel hose and a hose clamp to seal the leak, and it seems to have stopped leaking. One of the wires leading from the plate is stripped badly, and I guess this is probably related to problems I've had with gas gauge working. I taped the wire for now but depending on what I replace I might need an actual solution.
So my questions are... Can I get a replacement fuel sending unit assembly? Anything I find online just seems to replace the part inside the tank, and not the plate and gasket on top. Could I call the dealer and have them order the piece(s)?
Is the hose clamp a suitable solution, or am I just asking to be burned alive?
Lastly, should I sand and then spray WD40 or some other rust solution on the various rusty parts of my car? There seems to be quite a bit (I live in New York). I'm not sure where the car was or what happened to it before I got it 18 months ago...
Thanks again for the help, Thomas