How to Remove the Fuel Tank in Vehicles

by Contributing Writer; Updated June 12, 2017

There are three reasons Vehicles which you will need to remove the gas tank from your Vehicles to replace the fuel pump assembly; to replace the gas tank; or to flush out the gas tank if it has taken on bad or dirty gasoline. You can remove the tank itself in less than an hour, as it is held up by two metal straps and the necessary wiring and hoses. You can easily reach the components inside the tank once the tank is down on the ground. Simply unscrew the top on the tank to access the needed components.

Under The Hood:

 How to Remove the Fuel Tank in a Jaguar XJ6

Disconnect the negative terminal of the battery and set it aside.

Use a car jack to lift up your vehicle. Place jack stands under each wheel to ensure safety.

Remove the fuel-filling cap to release any pressure in the fuel tank. This is the cap that you remove when you are putting gas into your vehicle.

Locate the drain plug on the bottom of the fuel tank. Place a large bin under it that can hold the gasoline that is currently in the tank.

Remove the drain plug by rotating it counterclockwise. Allow the fuel to empty into the collection bin.

Remove the fuel filler assembly from the filler neck by removing the clamp that secures it. The clamp can be loosened by removing the screw that tightens it.

Remove the three bolts that secure the fuel filler assembly.

Slide the rubber boot down the neck of the fuel tank.

Remove the spare tire from your vehicle and remove the spare tire mount by removing the three bolts that secure it to the body of the vehicle.

Disconnect the vapor return line, canister vent line and fuel lines from the fuel tank. Disconnect them by using pliers to remove the pins and turning the connectors counterclockwise to loosen them.

Remove the two retaining bolts connect the fuel tank restraining straps.

Remove the fuel tank from the vehicle.

Items you will need

  • Car jack

  • Jack stand

  • Large container to collect fuel

  • Screwdriver

  • Socket set

  • Pliers

 How to Remove the Fuel Tank on a Honda 300 4x4 ATV

Remove the four bolts securing the front right and left body panels to the frame. The bolts will be in clear view along the edge of the panel. Use the ratchet and corresponding sized socket from the ratchet set to remove the bolts.

Pull the front right and left body panels off the frame of the Honda. Turn the gas valve between the fuel tank and the carburetor to the "Off" position.

Place the five-gallon bucket under the carburetor. Using pliers, compress the small metal clamp that secures the fuel hose to the top of the carburetor. Pull the hose off of the carburetor and drain the fuel into a bucket.

Using a ratchet set, remove the two bolts securing the fuel tank to the frame at the top of the fuel tank. Pull the fuel tank off the frame of the Honda ATV.

Items you will need

  • Ratchet set

  • Five-gallon bucket

  • Needle nose pliers

 How to Remove the Fuel Tank From a Dodge Grand Caravan

Twist off the gas cap. Pop the hood and locate the Schrader valve on the fuel rail at the front of the engine. Connect the fuel pressure release hose to the Schrader valve. Put the other end of the hose into the drain pan and let the fuel drain into the pan. Remove the fuel pressure release hose from the Schrader valve.

Lift up the Grand Caravan with the jack and lower it onto a set of four jack stands. Look underneath the minivan and locate the rubber fuel filler neck running to the gas door. Unscrew the hose clamp connecting the rubber hose to the gas door, using the flat-head screwdriver.

Unplug the wiring harness from the top of the gas tank with your hand. Push together the quick-release fittings on the fuel lines leading into the gas tank with your hand, then pull the lines off the gas tank.

Position the jack beneath the center of the gas tank and lift it up until it supports the tank. Unbolt the gas tank from the chassis of the Grand Caravan with the 3/8-inch ratchet, extension and sockets.

Lower the jack carefully until you can access the fuel filler neck hose. Pull the hose off the gas tank and lower the tank to the ground. Pull the jack out from under the Grand Caravan with the tank on top of the jack. Pull the tank off the jack and away from the minivan.

Items you will need

  • Fuel pressure release hose tool

  • Drain pan

  • Jack

  • Jack stands

  • Flat-head screwdriver

  • 3/8-inch ratchet, extension and socket set

 How to Remove the Gas Tank on an F-250

Locate the gas tank at the back of the truck. The tank will be situated behind two straps under the bed.

Drain the gas tank by unscrewing the drain plug with a crescent wrench. Allow the gas to drain in to a large drain pan. When the tank is fully drained, tighten the plug back to the tank.

Place a jack under the tank and raise the jack to bottom of the tank. This will help catch the tank when the straps are removed.

Unbolt the straps with a socket wrench. There are two bolts per strap. Remove the straps and place them out of the way.

Allow the tank to drop on to the jack. Lower the jack enough to access the top of the gas tank.

Disconnect the wiring and hoses that are installed to the top of the tank. The wiring can be disconnected at the wiring connector by pulling the tabs up and sliding the connector away from the other connector. The hoses are held to the piping by quick-disconnect fittings. Remove them the same way.

Loosen the hose clamp at the back of the tank. The attached hose is to the filler neck. Pull the hose off the tank once the clamp is loosened.

Lower the gas tank to the ground. Slide it out from under the truck.

Items you will need

  • Jack

  • Socket wrench

  • Socket set

  • Drain pan

 How Do I Remove the Gas Tank From a 1998 Ford Explorer?

Crawl underneath the SUV and locate the fuel tank next to the rear axle. Unbolt the skid plate, if so equipped, with a 3/8-inch ratchet and socket.

Remove the fuel filler neck from the gas tank with a flat head screwdriver. Place a wood block on the head of a jack and lift it up until the wood contacts the base of the gas tank.

Unbolt the straps securing the tank to the chassis with the 3/8-inch ratchet, extension and sockets. Slowly lower the tank until you can access the top of the gas tank. Remove the fuel lines from the sender with the flat head screwdriver and unplug the wiring. Lower the tank the rest of the way, holding it steady with one hand.

Items you will need

  • Jack

  • 3-foot long wood block

  • 3/8-inch ratchet, extension and socket set

  • Flat head screwdriver

 How to Remove a Gas Tank From an R1

Allow your R1 to sit for about two hours with the engine off. This will reduce the fuel pressure, thereby reducing fuel leakage.

Peel back the rear edge of the rider seat. This exposes two metal bolts. Remove them using a 5mm Allen wrench. Grasp the rider seat and lift it off.

Remove the Phillips screws (three per side) from the side panels. Push the panels forward to remove them.

Remove the two 5mm Allen bolts that secure either side of the gas tank. Remove the 5mm Allen bolt at the front part of the gas tank, and then remove the Allen bolt from the rear part of the tank.

Lift the front part of the tank. If you wish to remove the tank to replace the air filter, it's not necessary to remove the connections, hoses or fuel line. If you want to completely remove the gas tank, you'll need to disconnect the items.

Squeeze the spring clamps on the two hoses. Pull the two hoses away from the gas tank.

Unplug the two connections on the bottom of the gas tank. One is green, the other is white. Press the tabs to unhook them.

Remove the plastic connection from the bottom of the fuel line. Squeeze the side tabs on the fuel line connection. Pull the line away. A small amount of fuel will likely leak from the line (but not the tank). Be prepared for this; have suitable shop towels nearby. Try to prevent any fuel from getting on your clothing.

Items you will need

  • 5mm Allen wrench

  • Phillips-head screwdriver

  • Shop towels

 How to Remove the Gas Tank From an Astro Van

Park your Astro van on a level surface and engage the emergency brake. Put a chock block under one of the front tires. Open the hood and disconnect the negative cable from the battery.

Locate the fuel filter and disconnect the line from the tank feeding into the filter to relieve pressure in the line. The fuel filter on an Astro van will be under the van, on the fuel line, beneath the rear seats and slightly in front of the gas tank. The fuel filter will look like a cylinder placed into the actual fuel line. Disconnect the line closest to the tank by loosening the hose clamp with a flathead screwdriver and pulling the hose off.

Jack the rear of the van up and support it with jack stands. Do this on both sides of the van.

Reach up and loosen the hose clamp (with your flathead screwdriver) connecting the fill pipe from the gas filler hose. The gas filler hose is attached to the gas cap. Look up inside the car on the side where your gas cap is located and you will see the clamp.

Use a socket wrench to remove the bolt holding the bracket of the fill pipe in place on the frame. Once you have removed the bolt, pull the fill pipe down and away from your gas tank.

Slide under the car and look up at the gas tank. You will see that there is a molded metal shield bolted to the frame of the car that protects the tank. There are four bolts located at the four corners of the tank. Remove the bolts and pry the shield from position. Let the shield drop down and pull it out from under the car.

Push the car jack in and under the gas tank. Raise the jack till it touches the bottom middle of the tank and presses upwards on the tank slightly. Use the pressure from the jack to keep the gas tank stable and in place until you have removed the remaining bolts and are ready to lower the tank.

Disconnect all the fuel lines and electrical connections from the fuel tank. Locate these by following the lines back from the fuel filter to where they connect with the tank. Undo the hose clamps on the lines and pull the lines out. Unplug the electrical sensor by squeezing the side levers on the connector and pulling the two pieces apart.

Remove the tank-holding straps by undoing the bolts from both sides of the straps (there are two straps) and pulling the straps from around the tank.

Use the jack to lower the gas tank out of position. Keep one hand on the tank to stabilize it as you remove it.

Items you will need

  • Chock block

  • Car jack

  • Jack stands

  • Flathead screwdriver

  • Socket set

  • Pry bar

  • Tailor's chalk (if needed)

 How to Remove the Gas Tank in an F150

Park the vehicle in a dry and well-lit work area that has plenty of maneuvering space.

Jack the F-150 up in the four designated places near each tire. Jacking up one area at a time, place jack stands under each area. Extend the jack stands to their highest point to maximize your work space under the vehicle. You will have suspended the vehicle in mid-air.

Post your fire extinguisher in a easily accessible place in case of emergency. Locate the gas tank, which is at the rear of the truck in between the back tires. It is very large and reads. "Danger gas tank, flammable fluids inside." Drain the gasoline from the tank by removing the plug near the rear side of the tank. The plug will twist off with medium pressure applied.

Place your hydraulic under the gas tank. Elevate the jack 3 inches from touching the middle of the tank. The jack is there to reduce the weight of the tank when you disconnect it.

Lay down under the F-150 with yourself at one end of the tank and your assistant at the other end. With your bolt extractor, loosen the the two straps that are mounting the tank to the truck. The straps have a 7/8 bolts on each end, equaling four bolts.

Wiggle the tank using both hands placed at each corner. The person closest to the front of the vehicle will be applying pressure to push the tank out towards the person in the rear. This will take some muscle, patience, and maneuvering, but the tank should come out safely. Let the tank rest on the hydraulic jack and guide it out from under the truck.

Items you will need

  • Fire extinguisher

  • High-powered drill/ bolt extractor

  • 4 jack stands, 1 hydraulic jack

  • Gasoline drain bucket

About the Author

This article was written by the It Still Runs team, copy edited and fact checked through a multi-point auditing system, in efforts to ensure our readers only receive the best information. To submit your questions or ideas, or to simply learn more about It Still Runs, contact us.