Changing my fuel tank, questions!
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Changing my fuel tank, questions!
So i tried to patch my tank it has a few tiny holes....i used some "seal all" it didn't really work too well and the gas started seeping under neath it. So since it's getting close to winter and the tank is pretty rusted i may as well spend the $200 and get a new tank and some straps.....
My main questions i guess are....is there any special tools i will need to do this job? I have a friend to help so I'm not too worried about that. I just hope it goes smoothly lol.
My main questions i guess are....is there any special tools i will need to do this job? I have a friend to help so I'm not too worried about that. I just hope it goes smoothly lol.
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I just put a new tank in my 1997. It was the 24.5 gallon. What size is yours is located before or after the rear axle? It was a pain the but. Some things you should know get a jack to support the tank, get it as empty as you can(under a quarter preferable), make sure you have new straps standing by. Remove two bolts holding straps with an air tool makes it easy. Take some time now and soak it with penetrating oil, do that two or three times a day and right before you plan on taking it out. Remove the two filler neck hoses right next to frame first, remove straps drop tank four or five inches at most now there are two fuel lines going from the sending unit to truck remove those use fuel line removal tool much like this one http://www.napaonline.com/Search/Det...096_0006398599
Now there is a electrical connection to sending unit located on frame disconnect that. There is also a vacuum hose to disconnect near the sending unit. In the rear of the tank there is one hose clamp and another electrical connection remove those. Drop tank, remove sending unit with socket wrench set in new tank asap. Remove vacuum hose connections carefully with channel locks, don't break these there dealer parts. The last thing to take out is the evap sensor on rear of tank soak with penetrating fluid be as gentle *** possible, have your buddy push down as you spin with channel locks. Once there are out clean with a rag soak seal with a little motor oil to insure good seal. I broke the evap sensor I got a discount but it cost me 83 bucks so be gentle. Before re instillation insure straps are correct size and swap the rubber from the old to the new. There is also a rock sheild that needs to be taken off the old and on the new. Also replace the sending unit gasket new tank should come with one. thats all i can think of. This is for a 1997 f150 4.6 ext cab 3rd door, i dont know what your vehicle is but I hope it helps in some way.
Now there is a electrical connection to sending unit located on frame disconnect that. There is also a vacuum hose to disconnect near the sending unit. In the rear of the tank there is one hose clamp and another electrical connection remove those. Drop tank, remove sending unit with socket wrench set in new tank asap. Remove vacuum hose connections carefully with channel locks, don't break these there dealer parts. The last thing to take out is the evap sensor on rear of tank soak with penetrating fluid be as gentle *** possible, have your buddy push down as you spin with channel locks. Once there are out clean with a rag soak seal with a little motor oil to insure good seal. I broke the evap sensor I got a discount but it cost me 83 bucks so be gentle. Before re instillation insure straps are correct size and swap the rubber from the old to the new. There is also a rock sheild that needs to be taken off the old and on the new. Also replace the sending unit gasket new tank should come with one. thats all i can think of. This is for a 1997 f150 4.6 ext cab 3rd door, i dont know what your vehicle is but I hope it helps in some way.
Last edited by piston91; Nov 18, 2010 at 09:55 PM.
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Joined: Oct 2005
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From: MI
I've dropped mine quite a few time to replace the pump sock. Easy job getting it out, NO special tools needed that I recall. You just pop the rear vent to siphon fuel and the rest is cake, - or as explained above.
If you need a new filler neck overflow (overflow lines rust out) , There was a guy on ebay selling those , - new and cheap.
If you need a new filler neck overflow (overflow lines rust out) , There was a guy on ebay selling those , - new and cheap.
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Thread Starter
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Senior Member
Joined: Oct 2009
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I just put a new tank in my 1997. It was the 24.5 gallon. What size is yours is located before or after the rear axle? It was a pain the but. Some things you should know get a jack to support the tank, get it as empty as you can(under a quarter preferable), make sure you have new straps standing by. Remove two bolts holding straps with an air tool makes it easy. Take some time now and soak it with penetrating oil, do that two or three times a day and right before you plan on taking it out. Remove the two filler neck hoses right next to frame first, remove straps drop tank four or five inches at most now there are two fuel lines going from the sending unit to truck remove those use fuel line removal tool much like this one http://www.napaonline.com/Search/Det...096_0006398599
Now there is a electrical connection to sending unit located on frame disconnect that. There is also a vacuum hose to disconnect near the sending unit. In the rear of the tank there is one hose clamp and another electrical connection remove those. Drop tank, remove sending unit with socket wrench set in new tank asap. Remove vacuum hose connections carefully with channel locks, don't break these there dealer parts. The last thing to take out is the evap sensor on rear of tank soak with penetrating fluid be as gentle *** possible, have your buddy push down as you spin with channel locks. Once there are out clean with a rag soak seal with a little motor oil to insure good seal. I broke the evap sensor I got a discount but it cost me 83 bucks so be gentle. Before re instillation insure straps are correct size and swap the rubber from the old to the new. There is also a rock sheild that needs to be taken off the old and on the new. Also replace the sending unit gasket new tank should come with one. thats all i can think of. This is for a 1997 f150 4.6 ext cab 3rd door, i dont know what your vehicle is but I hope it helps in some way.
Now there is a electrical connection to sending unit located on frame disconnect that. There is also a vacuum hose to disconnect near the sending unit. In the rear of the tank there is one hose clamp and another electrical connection remove those. Drop tank, remove sending unit with socket wrench set in new tank asap. Remove vacuum hose connections carefully with channel locks, don't break these there dealer parts. The last thing to take out is the evap sensor on rear of tank soak with penetrating fluid be as gentle *** possible, have your buddy push down as you spin with channel locks. Once there are out clean with a rag soak seal with a little motor oil to insure good seal. I broke the evap sensor I got a discount but it cost me 83 bucks so be gentle. Before re instillation insure straps are correct size and swap the rubber from the old to the new. There is also a rock sheild that needs to be taken off the old and on the new. Also replace the sending unit gasket new tank should come with one. thats all i can think of. This is for a 1997 f150 4.6 ext cab 3rd door, i dont know what your vehicle is but I hope it helps in some way.
Wow was NOT expecting that thorough of a HOW TO but thank you very much!!
Thanks to you too jbrew.
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Joined: Oct 2005
Posts: 25,641
Likes: 19
From: MI
No problem, yea, use plenty of WD40 removing those vents on top of the tank. Work it in a little, then 1/4 - 1/2 turn counter clockwise, they pop out. they seal with a big rubber O-ring.