How to Replace the Gas Tank in Vehicles

by Contributing WriterUpdated June 12, 2017

Replacing the gas tank on your Vehicles is a simple project you can do yourself to save a costly repair bill. Rust, severe dents or leaking tanks are all candidates Vehicles replacement. The tank is located Vehicles the rear of the Vehicles just under the cargo area. It is held in place using two steel straps that attach to the frame rails and pass under the tank, holding it snug against a set of mounts on the body. It can be helpful to have a second person on hand to balance the tank during removal and installation, but it can be done by yourself if you don't have help available.

Under The Hood:

 How to Replace the Gas Tank in a Jeep Cherokee

Verify that your gas tank is empty, or drain the gas with a siphon hose before removing it.

Raise the rear of the Jeep with a floor jack placed under the rear differential. Support the Jeep on a set of jack stands under the rear axle tubes. Work on level, solid ground so the Jeep can not move.

Place a jack under the old tank to support it as you remove the bolts. Locate the two nuts on the J bolts on the front of the tank. Remove the nuts using a deep socket and ratchet or wrench. If the bolts are heavily rusted, you might need to cut them with a reciprocating saw and replace them.

Let the straps drop to the ground after the J bolts are removed and slowly start to lower the tank using the floor jack. On the front of the tank you will see the electrical connections and fuel lines that attach to the tank.

Remove the filler hose from the filler neck inlet on the tank using a screw driver to remove the hose clamp.

Remove the fuel lines from the tank. On older models you will need a screw driver to remove the hose clamps and remove the rubber hoses. On newer models you will need a tool to remove the fittings that can be purchased or rented at most auto parts stores.

Unplug the electrical connections that run from the Jeep body to the tank and lower the tank to the ground. Remove the tank from under the Jeep so you can remove the fuel pump and sender from the tank.

Locate the locking ring that holds the fuel tank sending unit and fuel pump in the tank. Remove it by turning it counterclockwise until it unlocks. Use a flat screw driver and a hammer to turn it, being careful not to damage it.

Remove the sender and pump from the tank and set it into the new tank, orienting it just as it was in the old tank. Install a new gasket and the locking ring to secure it.

Position the new tank under the Jeep and raise it with the jack until you can reinstall the fuel lines and electrical connections. Raise the tank the rest of the way and support it with the floor jack and a piece of wood.

Reinstall the filler neck hose to the inlet on the tank and secure with a hose clamp. Tighten it with a screwdriver, but do not over tighten the clamp as it will damage the rubber hose.

Raise the tank the rest of the way into the Jeep and install the tank support straps. Install the nuts onto the J bolts and tighten them until the straps are solidly supporting the tank. It should be tight, but do not tighten the nuts so much that you dent or crush the tank with the straps.

Place your jack under the rear differential housing and raise the Jeep off the jack stands. Remove the stands and lower the Jeep to the ground. Add fuel to the tank, check for any leaks and test run the Jeep.

Items you will need

  • Siphon hose (optional)

  • Jack

  • Jack stands

  • SAE and Metric socket set

  • SAE or Metric wrench set

  • Reciprocating saw

  • Screwdrivers

  • J bolts

  • Fuel tank

  • Fuel tank straps

 How to Replace a Gas Tank in a Ford F-150

Slide the floor jack under the rear of the F-150 and raise the jack up until the head is touching the bottom of the gas tank.

Open the fuel door and disconnect the fuel filler neck flange with the socket set. If your F-150's gas tank has a removable filler neck, you do not need to do this. If the tank and filler neck are one assembly, depending on the year and configuration of your F-150, you may need to access the flange fasteners from underneath.

Unbolt the fuel tank retaining straps and allow them to hang. Lower the fuel tank slowly with the floor jack, while your helper holds the tank steady. Once it has come down a few inches, reach in and disconnect the wiring harness to the fuel pump and the fuel lines. Newer-model F-150s may require you to disconnect the fuel filler neck during this step also.

Lower the tank the rest of the way down, making sure none of the lines or filler neck are interfering with the tank removal, and slowly guide the tank backwards and out from underneath the F-150. You may need your helper for this.

Pick the tank up off the jack and set it aside. Wrap the rag around the tip of the screwdriver and place the tip on the fuel pump retaining flange. Tap the screwdriver with the rubber mallet to loosen the ring so you can remove the fuel pump. Insert the pump into the new tank, with a new o-ring.

Place the new tank on the jack and roll it underneath the F-150. Raise the tank up until you can reconnect the fuel lines, wiring harness and filler neck. Raise the tank all the way and then pull the retaining straps back into position and reinstall the retaining strap bolts.

Reinstall the filler neck flange in reverse of how you removed it, if you needed to remove it at all.

Items you will need

  • Socket set

  • Floor jack

  • Helper

  • Screwdriver

  • Rag

  • Rubber mallet

  • New fuel pump o-ring

  • New tank

 How to Replace the Gas Tank on a Subaru Legacy

Park your Subaru Legacy on a flat surface. Lift the rear end of the vehicle in the air with your car jack and place the car on jack stands.

Pop the hood and remove the black negative connector on the battery and close the hood.

Put your safety goggles securely on to protect your eyes from fuel.

Drain the remaining fuel in the defective gas tank. Use the fuel siphon set and place the hose in the tank from the gas cap, create suction with the vacuum pump from the set, and empty the tank into the drain pan.

Remove the exhaust manifold assembly connecting to your gas tank. Use the metric ratchet set to detach the bolts. The exhaust manifold set includes the exhaust pipe, muffler, and attached fuel lines. Save the bolts for re-assembly.

Remove the fuel filler pipe attached at the fuel housing outlet of your Legacy. Use your metric ratchet set to unbolt the fuel filler pipe, and use the flathead screwdriver to remove the brackets hoisting the pipe. Place the bolts and screws aside in a separate pile for the replacement gas tank.

Remove the defective gas tank. Use your metric ratchet set to remove the brackets by detaching the bolts holding the tank in place. Save the bolts.

Mount the replacement gas tank. Bolt the new gas tank with the brackets and bolts from Step 6 with your metric ratchet set. Securely fasten the brackets into place.

Attach the fuel filler pipe to your Legacy's fuel housing outlet. Use the bolts and screws from Step 5 to re-assemble into place, fastening the bolts and screws with your metric ratchet set and flathead screwdriver.

Bolt the exhaust manifold assembly onto the replacement gas tank. Use the metric ratchet set and the bolts from Step 4 to re-attach the assembly. Check the fuel lines thoroughly for any leaks.

Items you will need

  • Safety goggles

  • Car jack

  • Replacement gas tank

  • Metric ratchet set

  • Flathead screwdriver

  • Fuel siphon set

  • Jack stands

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