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Old 12-30-2011, 01:09 PM   #1
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Gas tank removal help needed 99 TJ

Need to pull out the tank, I have it most of the way out. 99 TJ

1) I cannot figure out how to disconnect the fuel pump wiring clip. Please tell me the secret. I hate electrical connectors. I can never figure them out. (first picture)

2) I cannot get the large flange to loosen up to remove the fuel pump. I read somewhere to hit it with a drift but I have been beating the snot out of it and it wont budge! (Second picture)
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Old 12-30-2011, 01:45 PM   #2
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Go to You Tube. There are some great vids out there for this precise job.

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Old 12-30-2011, 02:19 PM   #3
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For the connector, the red part is a lock that slides out a bit first. Should be easy after that.
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Old 12-30-2011, 02:47 PM   #4
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I dont see any youtube videos that will help?? Daemon, I thought maybe they had something to do with it but they dont seem to slide. Maybe i wasnt trying hard enough!
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Old 12-30-2011, 02:59 PM   #5
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Look for ones that address skid plate replacement. you have to drop the tank to do that and there are some very detailed videos out there.
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Old 12-30-2011, 03:55 PM   #6
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Aluminum Gas Tank Skid - 2

Try this from Stu's site.

I have pulled mine and it can be a pain to get the connectors apart. Be patient or the red tabs could break.
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Old 12-30-2011, 05:17 PM   #7
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for the fuel pump ring you can get a strap wrench for cheap at lowes or sears etc. it is what I used and was an easy removal.

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Old 12-30-2011, 06:31 PM   #8
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I bought one of those strap wrenches and it still wont budge. I hit it with penetrating oil tonight so maybe tomorrow...
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Old 12-31-2011, 07:46 AM   #9
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my bud and i replaced my skid on my 98 earlier this week. the red clip is the whole deal.... we struggled with it too... finally used a very small flat blade screw driver and jimmied at it until a few grains of grit that had become embedded in the clip and the housing. the grit had worked its way into the slide mechanism over 13 years and fused it all pretty tight.... it needed to be worked in a awkward position too. it came apart after a few minutes... but it is a PITA....
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Old 12-31-2011, 07:55 AM   #10
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becareful with the fuel pump locking ring, its plastic. dont use a drift and hammmer or what not, if you break it its not real cheap, they do sell a tool for it. GenRight Off Road Part GST-1001 - Fuel Pump Lock Ring Tool not saying you have to buy this tool but might be cheaper than breaking the ring and trying to buy a new one
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Old 12-31-2011, 08:19 AM   #11
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Does the red clip come all the way out or does it just slide over?
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Old 12-31-2011, 08:43 AM   #12
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Quote:
Originally Posted by davekippen View Post
Does the red clip come all the way out or does it just slide over?
If I remember right it should slide then you gently squeeze them together on it should release. I think just on the 05-06 models the red tab comes completly out.
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Old 12-31-2011, 10:16 AM   #13
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If the red clip comes all the way out it wont hurt anything is just a saftey clip so the connector does come disconnected on its own
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Old 04-29-2013, 02:38 PM   #14
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when i just did mine I broke the red clip so now the plugs do not stay connected on their own without the help of electrical tape

can these be easily replaced?
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Old 04-29-2013, 04:21 PM   #15
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Those red clips break very easily be careful they only come out a little bit.
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Old 04-30-2013, 05:49 AM   #16
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yeah really cheap design
so since mine is broken are they easy to fix/replace
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Old 05-01-2013, 05:51 AM   #17
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if you can find a replacement one, I would check the junkyard first, they just press in. super simple.
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Old 05-01-2013, 08:25 AM   #18
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I think you should be fine taping it. Not ideal obviously, but it may prove hard to find a replacement.

That locknut is a frickin' bear to get off. Not to mention, once it is actually off it is a PIA to get back on because it doesn't want to line up with the grooves. Cheap PIA design. To get it off, tap the ridges on the locknut portion with a hammer and large prybar. Something that has some weight to it. Be careful obviously, but that should have enough weight to move it after some tapping. I found using a screw driver to tap with a hammer didn't work because it didn't have enough weight and width to turn the lock nut. With regards to getting the locknut back on, that strapwrench will actually come in handy. Just keep at it man. It is just generally a PIA process.

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