Gas Tank Replacement
Thread Starter
Montani Semper Liberi
Joined: Dec 2012
Posts: 265
Likes: 9
From: West Virginia
Gas Tank Replacement
The gas tank on my '02 FX4 Screw started weeping gas through the bottom in two places in the last month. I don't quite have 60k miles on the truck, but the tank is rusting through. I picked up a good used tank for $75 through a local salvage parts dealer.
I plan to clean it up good and shoot it with primer and undercoating before I do the swap. Is this going to be a hard job to do a drop and swap? I don't have the man power to remove the bed so I have to do it from below.
A google search gave me the impression that all i have to do is to loosen the filler hose, jack the tank up and the straps will unhook and unplug the pump and accessories as you drop the tank... sounds too easy, whats the catch?
Thanks any tips you guys may have!
I plan to clean it up good and shoot it with primer and undercoating before I do the swap. Is this going to be a hard job to do a drop and swap? I don't have the man power to remove the bed so I have to do it from below.
A google search gave me the impression that all i have to do is to loosen the filler hose, jack the tank up and the straps will unhook and unplug the pump and accessories as you drop the tank... sounds too easy, whats the catch?
Thanks any tips you guys may have!
Thread Starter
Montani Semper Liberi
Joined: Dec 2012
Posts: 265
Likes: 9
From: West Virginia
After unbolting the gas tank straps, just twist and remove the straps in order to get them out of the way.
When using a quick-connect gas line removal tool, twist the tool back and forth to work into the groove and loosen the o ring before pulling. I don't know why, it just works.
Took me 6 hours, trying to get the damn fuel line disconnected was the worst part. Tank was $75 used from a local salvage parts retailer.
When using a quick-connect gas line removal tool, twist the tool back and forth to work into the groove and loosen the o ring before pulling. I don't know why, it just works.
Took me 6 hours, trying to get the damn fuel line disconnected was the worst part. Tank was $75 used from a local salvage parts retailer.
Junior Member
Joined: Dec 2013
Posts: 9
Likes: 1
Here's what I learned from my recent experience. When you Pick up your quick connect tool if you don't already have a set buy the sturdier set. I cheaped out and grabbed the thin walled set and it could not slide all the way in.
If you are swapping the filler hose from the old tank to the new tank. Don't push the hose all the way flush to the tank. Look at the rust line on the old tank and push it about the same amount onto the new tank. Every half inch helps when reconnecting and clamping to the filler neck.
The Black pressure sensor is about 90 bucks at the auto store. If your new tank doesn't have it take your time removing. The middle piece is thin, too thin to take the torque needed to remove in one pull.
I took advice from another member and strung straps from one side to the other at the front and back of the tank and lowered the tank that way. Than when you disconnect the filler hose you can rotate the tank to access the connectors a little easier off your back. Its not a bad job, one time through and you'll be a pro. Good luck.
If you are swapping the filler hose from the old tank to the new tank. Don't push the hose all the way flush to the tank. Look at the rust line on the old tank and push it about the same amount onto the new tank. Every half inch helps when reconnecting and clamping to the filler neck.
The Black pressure sensor is about 90 bucks at the auto store. If your new tank doesn't have it take your time removing. The middle piece is thin, too thin to take the torque needed to remove in one pull.
I took advice from another member and strung straps from one side to the other at the front and back of the tank and lowered the tank that way. Than when you disconnect the filler hose you can rotate the tank to access the connectors a little easier off your back. Its not a bad job, one time through and you'll be a pro. Good luck.
