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Old 10-24-2009, 08:21 PM   #1
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94 Fuel Tank Removal

I am replacing my fuel tank tomorrow due to a leak that developed recently. Does anyone have any advice or tips for this? I have a manual and will use that to guide me. Any input is appreciated, thanks!

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Old 10-24-2009, 09:42 PM   #2
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Make sure it's empty and have a friend to help.
Somewhere around here there's a thread where I R n R'd the tank on my 91.
Don't remember if I gave much of a description but there might be some info in there.

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Old 10-24-2009, 09:59 PM   #3
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First put a floor jack under the center of the tank to support it. Then take the screws out of where the gas filler neck attaches to the tub. Then remove the bolts that attach the font of the skid plate to the crossmember under the rear set. I believe they are 1/2" nuts. Then remove the nuts from under the rear crossmember. Don't remove the two from the rear of the gas tank skid that have the long bolts sticking out of them. Those two are the threaded ends of the straps that go over the top of the tank to hold it in place in the skid. Wait untill you have the tank and skid on the ground and oil the threaded ends of the straps. I would then hold the end of the sraps with a pair of plyers as you remove the nuts from the end of them. This will help prevent breaking the threaded ends off of the straps and you won't have to either repair or buy new straps. The electrical wiring going to the tank has a connection that can be undone about a foot or so from the tank. You will see the plug when you drop the tank. Take the rubber fuel lines off of the tank by loosening the hose clamps on the metal ends of the sending unit and sliding the hoses off of them. Make sure to mark which hose goes on which tube of the sending unit.
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Old 10-24-2009, 11:03 PM   #4
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thank you both. my only concern is the two threaded strap ends at the rear. the threads are pretty rusty/ almost not existent. I'm hoping the nuts will come off so I can reuse the straps. If not I guess I will have to go get the universal straps from napa or somewhere like that...
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Old 10-25-2009, 08:11 PM   #5
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i dont mean to jack your thread but, does anyone have an pointers for taking the bolts out of the rear of the gas tank, there carriage bolts and they keep spinning in place.. tahnks.
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Old 10-25-2009, 09:15 PM   #6
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yeah, i had a b*stard of a time with those. I ended up breaking them all off and getting new hardware. I put a wrench on the head and a rachet on the nut and kept twisting and spraying with pb blaster until it wouldn't budge anymore. Then I used a drill and shaved the diamater of the bolt down...on two I broke them off with vice grips and the other i was able to twist in two. mapp gas would have worked better. hah.

anyone know about the recangular fuel bowl inside the tank? my new tank didn't come with one, so I epoxied it in my new tank. Probably not the best thing, but I didn't know what else to do...I was working in my dorm parking lot. Do you think the epoxy will be ok? it is supposed to be solvent resistant...on top of the epoxy, the sending unit pushes down on it..so i don't think it's going anywhere. any thoughts?
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Old 10-26-2009, 06:39 PM   #7
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okay, i waited 24 hours for the epoxy to cure and filled up the tank today. I put 20 gallons in it. It was only 15 before. I don't know the reason for this...but its pretty cool
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Old 10-26-2009, 09:04 PM   #8
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The 20 gallon tank has a shorter filler hose in the tank so it does not kick the pump off as soon as the 15 gallon one. The white bowl in the bottom of the tank is to prevent the fuel pump from sucking air should you run the tank that low on gas. The older tanks, I think 90 and older don't have the bowl, 91 to 95 have it. The sending unit should hold the bowl in place so it should be fine.

As for removing the bolts out of the rear of the gas tank skid, if they spin loose I use an angle grinder and just cut them.
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Old 10-27-2009, 10:36 AM   #9
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Quote:
The sending unit should hold the bowl in place so it should be fine.
that's what I thought too. thanks cj
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Old 10-31-2009, 11:38 AM   #10
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Originally Posted by ajeepthing View Post
i dont mean to jack your thread but, does anyone have an pointers for taking the bolts out of the rear of the gas tank, there carriage bolts and they keep spinning in place.. tahnks.
I'm trying to remove mine as well. I ended up getting 2 loose, still trying to get the last one off (having no luck). I sprayed liquid wrench and put a vise grip on the top of the bolt and used a socket on the bottom, the vise grip must of popped off about 100 times before they came loose. If the bolts weren't so rusty, this would of been a pretty easy job.
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Old 10-31-2009, 01:41 PM   #11
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If the bolts weren't so rusty, this would of been a pretty easy job.
well said
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Old 11-01-2009, 06:56 PM   #12
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i loosened the rear bolts enoguh where i could then use a sawzall, but the ones in the front i just used a good ole vise grip and a wrench! good luck.

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