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Mud 05-22-2011 12:01 AM

Dropping the Fuel Tank
On my 1993 YJ I finished dropping the fuel tank to solve a gas fumes issue and thought I would post a detail on what I had to do since a search failed to lead to a detailed thread.

I had an issue with the strong smell of gas coming into the cab while driving and surrounding the vehicle while parked. So dropping the tank begins

With the Jeep on a level surface and the battery disconnected I began.
  1. remove the Tag bracket
  2. remove the plastic surround the filler neck is connected to
  3. remove the filler neck from the plastic surround
  4. locate the plastic cover at the bottom left corner of the tub and remove or fold it out of the way
  5. remove the two hose clamps from the filler neck removing it from the hoses
  6. Place a floor jack under the skid plate and use a small piece of plywood to apply upward pressure on the tank
You are now ready to remove the nuts holding the tank on. There are five nuts along the back edge of the tank and three along the front above the rear axles. The nuts along the back edge include two nuts for the tank strap and do not need the be removed. They are the number 2 and 4 nuts from left to right on the back edge. The last three are just above the rear axle. Once you have these six nuts removed you can lower the tank a few inches so you can disconnect the wiring plug for the sending unit/fuel pump. You may also want to disconnect the fuel line connected to the vacuum line just in front of the rear axle.

At this point you should be able the lower the tank the rest of the way out. All of my hoses had enough length to sit on the floor. The are two hoses connected to the fuel pump. They will drain fuel once disconnected so have a container ready. You should now be left with two vent hoses connected with a tee that is connected the vacuum line mentioned above. And thats all there is to it.

The fume issue I had came from the vent line being crushed and torn apart. Once these lines where replaced all was good to go.

Now for a side note. While I was dropping my tank I lowered it too far before disconnecting everything and pulled the wire plug apart. This led to one of the wires ( middle wire ) no connecting when the plug was reconnected. Which gave me a fuel gage that always read FULL. So after dropping the tank a seconded time and rechecking things I found the wire issue and now all is good to go.

Do everything in reverse to replace the tank. So if you are worried about dropping the tank fear not. It is an easy job, trust me on some vehicles you have to just about remove the rear end completely to drop the tank. I hope someone finds this helpful.

bink 05-22-2011 02:02 AM

Thank You! Big help

buster01 05-22-2011 09:55 AM

Excellent job Mr. Mudd!! Could someone ad this to the "YJ Common issues thread fixes" please??!!

Driller 05-22-2011 11:01 AM

A really good write up. was just starting to have some issues with this myself. was going to replace gas tank skidplate. thanks.............Driller

Mud 05-23-2011 05:10 PM

Thanks for the kind words. I wish I had taken pictures but I never think about doing a writeup until the job is done.

zoomwide 11-20-2011 08:13 AM

Good write up Mudd. I am trying to drop the tank from my rust bucket 95 and it is a real challenge. Every nut rusted beyond recognition. So, forced to use a cutting wheel to cut out what I can. Gotta mind the sparks next to the fuel tank

yj93ben 11-20-2011 09:21 AM

Good write-up
Good write-up Mud, you might also mention that having a empty tank makes this a little easier. I know this is painfully obvious but, never-the-less, needs to be said.:thumb:

stevel22 12-01-2012 07:54 PM

Just went through the same thing but cant get it started. Wondering if I wired it wrong.
Do you know how I can find out the color coding of the wires?
Thanks alot.

Gearhed 12-02-2012 12:03 PM

Appreciate the write up, don't imagine there is much difference between the 93' and my 94'. I want to drop the tank, clean it out as well as the wiring and sending unit and hoses especially the vacuum line. One thing I haven't done is look for the fuel filter - if there isn't one I'll put one on it.
Would probably have been griping trying to find the bolts - your work is going to make it a lot easier.

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