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jlloyd 04-13-2011 07:34 AM

97 tj fuel tank leak
i have a leak in my fuel tank (i think i know where it is...) and i want to drop the tank out to fix it.

My first question is how do i drop the tank, is it as easy as just unsrewing the bolts and there it is or is there more to it. ( if you have pics please send)

second question is what would be the best way to seal the leak, epoxy?

Im on a broke budget so im trying to fix it without breaking the bank. If any one has some suggestions i would greatly appreciate it.

randy and teri 04-13-2011 10:17 AM

you have to consider the filler neck, fuel lines and wiring. be aware of the weight due to gas inside.
the best way is to put it on a couple milk crates to suspend it, drain the gas, cover the bottom with water so you can find the leak and weld it up or braze it. thats the best way. keep in mind, if you have a rust hole, than the metal surrounding the hole will be thin also.
autozone has kits for tank repair, i would probably use jb weld or a fiberglass patch if i were going that route.

KCrisp 04-13-2011 11:50 AM

It does drop straight down when you take the bolts out, BUT you need to address things like the vent lines, electrical and fuel line when it is part way down. Or you will break things, especially the plastic vacuum "T." The grounding strap is really easy to break and is too short to reach the tank if you let it down very far.

Is a '97 an ABS tank? If so are you sure you don't have a leak elsewhere like the filler or a vacuum line or something?

tjd1 04-13-2011 11:56 AM

Do not weld or braze the tank. My 97 is plastic. If it is isn't it has to be boiled out by a shop.:nonono:

jlloyd 04-13-2011 12:07 PM


im not sure if its an ABS tank ( not sure what that is...) but its a plastic tank and im almost sure the crack is right where the the fuel filler hose is. bought the jeep and the person put a 2 inch body lift and did not extend the hoses so i think the tension caused the crack. I plan on droping so i can extend hose and seal crack.

Dewry636 04-13-2011 12:36 PM

Unhook fuel line, vapor line and electrical fuel pump connection. All these should be accessible from the drivers side rear wheel area. You probably want to remove the drivers side rear wheel if you are not putting it on a vehicle lift to drop the tank. The electrical connection has a plastic clip that slides in from the side, I think. Check it over.

Remove fuel cap... remove screws that attach fuel filler neck. stuff a rag in it to avoid getting dirt down the hole when lowering the fuel tank. There is a ground strap up there as well, but mine wasn't attached, so I have no idea where it originally mounted.

Remove bolts from rear of tank skid plate. There is a bolt on the front side near the top of the passenger side rear shock. There are also a couple bolts on the front side of the fuel tank skid plate above rear drive shaft.

The tank will then come down.... it helps to have a near empty tank and a couple extra hands. Lower it down slowly while fishing fuel filler neck down through beside the frame (it's a tight fit) Make sure you stuff a rag in the fuel filler neck hole. Don't use the fuel cap like i did.... when it came down through, it broke my cap right off. Then I had to buy a new one.

Your fuel tank will be strapped to the skid plate. Unbolt the two straps... and it's finally free.

It's possible I may have missed some things, so use your own judgment when doing this procedure. I am not responsible for any mishaps or disasters that may happen due to these instructions. Use caution: No smoking during this procedure.

I replaced the skid plate... so I really have no idea how to fix the hole in your fuel tank. But this will help you get the tank out where you can see it.

jlloyd 04-13-2011 12:41 PM

Thanks dewry636, ill let you know how it goes this weekend. Im also installing a AA bracket for the binding problems with 4wd. Should be a fun weekend haha

randy and teri 04-13-2011 09:23 PM


Originally Posted by KCrisp (Post 1176168)
Is a '97 an ABS tank? If so are you sure you don't have a leak elsewhere like the filler or a vacuum line or something?

duh. i wasnt thinking as i just welded my rear tank on my f250. :banghead:

BLK00TJ 04-13-2011 09:29 PM

Rokman has a video on removing the fuel tank to install a skid plate. Looks fairly easy to me and you can fix the design flaw in the retaining straps while you're at it.

jlloyd 04-29-2011 02:35 PM

Just wanted to add that i put a new tank on ( junk yard tank). it was very easy. thanks for all the help

Bigbluetj 05-28-2011 07:40 PM

ok unless u want gas everywhere, pull the fuel pump relay from under the hood in the fuse box, then start ur jeep, it will start and cut off when all of the fuel in the lines and engine are gone, disconnect the filler hose from the bezle, then support it with a floor jack and wood, then unscrew the 7 bolts on the skid plate and lower it down,

YouTube - ‪Jeep Wrangler gas tank skid plate installation‬‏
this video shows how to install a high clearance skid, so it will show how to drop the tank!
keep jeepin!

jmpierce 05-28-2011 07:52 PM

2 Attachment(s)
My 03 Tj can be removed by removing these bolts and three on the back side I think 4 hose lines and one wire plug I just dropped mine pretty simple but it helps to have some extra hands

jmpierce 05-28-2011 07:54 PM

If yours has the plastic fuel line fittings with the u shaped pin be careful not to break as I did best of luck to u

Kevin W. Sanner 03-20-2014 04:47 PM

vacuum routing
Hey Guys, Can someone tell me where the vacuum line on my fuel tank goes too? I hooked the 2 vacuum outlets together with a tee an ran it along the frame to the front but not sure where it goes? Thank you.

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