Searching for a fuel tank for a 2002 Trooper, built after 9/30/2001.

 

That's going to be very difficult to do, same for the sending unit.
Maybe 5-6 yrs ago I had to replace both. I located what I was told was the last sending unit in the US ($500) and no tanks left ($1000)
After a month or so I finally located a used tank a few states away.

The next thing to do would have been to measure the old tank and find some other make/model of vehicle with a tank that size and get it and matching sender.

 

Many thanks for your thoughts on the fuel tank dilemma. I found a tank in Chicago but it's still in the vehicle and likely with the same condition since it's in the rust belt. I also have a line on a fabricator who can cut and repair the tank as well. However, like you found, the sending unit is 8-12 weeks from Japan and about $500.00. I was also told that Isuzu doesn't have any more tanks and considers this an obsolete part. I found a tank repair company in California - Gas Tank Repair San Diego California (orozcosautoservice.com), quite a long way to send a tank for me but it may be an option for some. We love this truck, and we would like to get another 5+ years out of it if possible.

 

Go for it, the epoxy will seal the seam leaks. The procedure is to put some gravel in the tank and slosh it around real good to knock loose any rust flakes and dirt. Clean the tank out, flush with water and dry thoroughly with an air hose. It's definitely something you could do yourself in your backyard if you're patient and thorough.

 

Many thanks for your thoughts on the fuel tank. The tank in Chicago ended up having the same issues as mine (rust belt), but we found one in a bone yard in AZ. In order to ship, they sprayed fiberglass inside the tank so there were no fuel remnants when shipped. Installed back in 2022 with a new pump and it's been working great. Two months after installing the tank, my wife was in a head-on with the truck. Totaled. She's fine, but with all the work we did, we bought it back from the insurance company and fixed it! Still rollin' with 165k.