The fuel tank is leaking again. I just put a new one in two years ago. What might be causing this problem? Has anyone else had this problem? Has anyone had any luck patching the holes/cracks?
Changing the tank is a bit of a PITA so any ideas so that this doesn't happen again would be great.

Only permanent fix is to find a shop willing to inert the tank with N2 or other non flamable gas and braze it, tank stop leak goop/putty only luck Iv'e had with it is slow leak to a drip, or eventually becomes a drip if it actually does stop the leak

That's really odd, i've had 3 of these trucks and never had a tank leak. Had to replace the sender/pump/sock a few times (the 3 were driven about 450,000 miles combined). Was it damaged by debris somehow or did it come apart at the seams? I've welded tanks in the past, filled them with water as much as possible after washing it out really good. The water displaces the fumes and no "boom-boom". Good luck with yours.
Don

Ignition in Diesel tank after washing out isn't much of an issue really, nor gas tank for that matter , but people git twiterpated about heat on a "FUEL TANK"
liability and all some shops will only do it if tank is "inerted", not that other methods won't work.

Multiple tank fails in same truck, does it happen in same location, that would lead me to suspect a cyclic stress fail, like tank is in a bind in the straps stressing/cracking of the tank over time, or do you have something rubbing it over time

I drive alot of gravel roads. I got to be thinking that some small stones may have gotten under the plastic shroud and rubbed thru. I will removing the tank this week to see what's going on. Thought about using a stop leak epoxy or even trying to braze it. Afterwards try spraying it with a rubberized undercoat. Figure anything can help.