Thread: Fuel tank differences between GEMS and Thor

Originally Posted by Scouse

I might have to buy an NTC5859 & find out.

I just checked. I have an NTC5859 in the garage plus another seal which I think is from a diesel. Both are a perfect sliding fit over the neck of the pump.

In the pics, the black ring is the NTC5859. I don't know what model LR the green seal is from.

I wonder what the diameter of the D2/Thor pump is directly below the top flange? One needs to measure there as the neck is tapered on the spare GEMS pump I have in the garage. The diameter of the neck on that pump is 110mm

Both the D1 and D2 pumps are 110mm diameter just below the top ring. A D2 pump fits into a D1 tank provided the D1 seal is used and the top flange is trimmed to the same slightly smaller diameter of the D1 pump. Their P38 analogues should be the same.



D2 pump in D1 tank, D1 clamp ring, D2 seal, D1 seal.



D1 pump, D2 pump, slightly wider top flange. D2 pump body is larger and D1 seal is a struggle to fit but it all goes in. You'll need to check the orientation of the outlet pipe versus the sender float as they may foul inside.

As for seals, it seems that the seal type for the original tank should be used even if you swap pumps.

And lastly: A D1 pump in a D2 tank using a D2 seal and clamp ring, looks like it should seal perfectly:

That's brilliant, B-U. Do you know what the green seal I've pictured above is from?

Originally Posted by p38arover

That's brilliant, B-U. Do you know what the green seal I've pictured above is from?

The green seal looks like the D2 (Thor) seal I played with today. It appears to have the same inwards facing lip and overall height. The one I have is quite perished and somewhat deformed so it's hard to be 100% sure.

BTW with all the pump seals I've dealt with the secret is to place them just under the pump housing top, insert them carefully without lubricant into the tank orifice, then lightly lubricate the pump housing flange with neat detergent and carefully rotate it in. The seal is dead easy to displace from its correct installed position unless the pump housing can ooze slowly through it.

Originally Posted by bee utey

Their P38 analogues should be the same.

I'd like to think so but I think there might be some differences due to the fact that the D2 Thor & P38 Thor use different seals.


If the green seal Ron has shown is a D2 Thor seal, it's quite different in design from the black seal next to it which is a P38 Thor seal.

I checked with Brad at KLR this arvo, the new seal he has ordered for me is a replacement for NTC5859.

Originally Posted by Scouse

I'd like to think so but I think there might be some differences due to the fact that the D2 Thor & P38 Thor use different seals.


If the green seal Ron has shown is a D2 Thor seal, it's quite different in design from the black seal next to it which is a P38 Thor seal.

I meant that the pump housings are probably very similar, especially as the D2 housing has two protrusions where the P38 has a breather elbow fitted.



And then you look at the picture of the Thor type long range tank and see that only the top surface of the seal will actually end up doing anything. I built a couple of D2 auxiliary tanks once and made sure the mounting plate had the groove machined in to better engage the second outer lip on the D2 seal. If the P38 Thor tank seal doesn't have the second lip so be it.

Pick your tank, pick your pump and a new seal that fits well enough to work.

I'm at KLR Auto and have just picked up the new seal WGQ500020 and it looks identical to the green seal except it's black.

I measured the hole in Scouse's fuel tank and it's 111 mm - 1mm bigger than the pump