how do i replace my gas tank?
Thread Starter
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Senior User
Joined: Dec 2010
Posts: 261
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how do i replace my gas tank?
this weekend i want to replace my rear fuel tank. right now they both leak so im in quite a pickle...they are cheap. i have never dont this before. is there a wright up on replacement of tanks or can someone walk me through it? any pics? im keeping everything else just replacing the tank. what tools are needed? anything special? tricks?
THANX I APPRECIATE IT!!!
THANX I APPRECIATE IT!!!
Posting Guru
Joined: Jul 2004
Posts: 2,244
Likes: 2
From: Cottage Grove, WI
Replacing either tank is pretty easy, heres some things that have helped me in the past
Remove the bed. You have to do this to remove the rear tank, it comes out from the top, makes replacing the front one MUCH easier
Do this with 1/8 tank of gas or less, any more and these things get heavy fast!!
You will need fuel line disconnect tools, and be VERY CAREFUL using them. If you damage the little metal internal clip that holds the line on, you will need to replace the whole line.
Id recommend replacing the fuel pumps at the same time, good luck getting the hold down rings out w/o damaging them.
Remove the bed. You have to do this to remove the rear tank, it comes out from the top, makes replacing the front one MUCH easier
Do this with 1/8 tank of gas or less, any more and these things get heavy fast!!
You will need fuel line disconnect tools, and be VERY CAREFUL using them. If you damage the little metal internal clip that holds the line on, you will need to replace the whole line.
Id recommend replacing the fuel pumps at the same time, good luck getting the hold down rings out w/o damaging them.
Thread Starter
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Senior User
Joined: Dec 2010
Posts: 261
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doesnt anyone look in their sig's? its a 92 f250 dual tanks... i have a benliner and a tool box in bed. i have to take tool box out to git bed liner out then take bed off? thats f'd up...they tank comes with gaskets and such for the stuff to be remounted...also both tanks leak so right now nothing is in either tank.. it leaked out all over the road..lol sucks. could i rent fuel line disconnect tools from advance auto parts? ive never used these b4. lets say i had to replace whole linf from newb damage... where do the line go? from tank to where? how hard is it to replace that? also what are hold down rings? if you could blue rebel could you wright me a step by step precedure for replacing it since you are so knowledgable? or is there a wright up somewhere. or IS THERE SOMETHING IN A CHILTONS MANUAL THAT WOULD SET ME IN RIGHT DIRECTION? i currently dont have the book yet..
Fleet Owner
Joined: Oct 2005
Posts: 20,786
Likes: 1,751
From: Kentucky
My Haynes manual has the instructions to R & R the fuel tank. Personally I think removing the bed is over-kill. Everyone has their favorite method. I replaced the rear fuel tank on my '92 F350 about a year and a half ago. I did not remove the bed, I lowered the tank using nylon ratchet straps.
I live in the rust belt so I was worried about getting the straps loose and other issues related to corrosion. The only casualty was the bolts/nuts holding the straps on. Everything else was fine. My replacement tank came with a new lock ring and o-ring, that was a good thing. The old lock ring was pretty much destroyed trying to remove it. The lock ring holds the fuel pump assembly in place on top of the fuel tank. The o-ring is used as a seal between the tank and fuel pump assembly.
Your fuel line fittings should use the spring lock coupling style fittings. They can be a real pain to break loose. You will need a fuel line release tool, if I recall it was 5/16" and 3/8". The supply and return fittings are different sizes. I had the fancy metal style removal tool, but one of those fittings refused to budge. I ended getting a cheap plastic set, that did the trick.
I live in the rust belt so I was worried about getting the straps loose and other issues related to corrosion. The only casualty was the bolts/nuts holding the straps on. Everything else was fine. My replacement tank came with a new lock ring and o-ring, that was a good thing. The old lock ring was pretty much destroyed trying to remove it. The lock ring holds the fuel pump assembly in place on top of the fuel tank. The o-ring is used as a seal between the tank and fuel pump assembly.
Your fuel line fittings should use the spring lock coupling style fittings. They can be a real pain to break loose. You will need a fuel line release tool, if I recall it was 5/16" and 3/8". The supply and return fittings are different sizes. I had the fancy metal style removal tool, but one of those fittings refused to budge. I ended getting a cheap plastic set, that did the trick.
Laughing Gas
Joined: Dec 2007
Posts: 959
Likes: 8
From: Imperial, MO
Agreed. You don't need to remove the bed to drop the tank. I just replaced the rear tank on my '95 F150 last year, and I lowered it by hand (only about 1/8 tank of fuel in it at the time). The hardest part was getting to the connections on the top of the tank, as you don't have much slack in the lines to work with. I've always had better luck with the aluminum removal tools over the plastic ones, but either one should get the job done.
-Rod
-Rod
pedant
Joined: Jan 2008
Posts: 23,576
Likes: 39
From: EXTREME southwest CT
Drop the spare tire, there's two straps with 15mm bolts.
I did a writeup a while back for an '89, don't know if there's any difference.
https://www.ford-trucks.com/forums/7...tank-leak.html
I had a lot of help in that thread.
I did a writeup a while back for an '89, don't know if there's any difference.
https://www.ford-trucks.com/forums/7...tank-leak.html
I had a lot of help in that thread.
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Elder User
Joined: Apr 2008
Posts: 841
Likes: 1
From: North Carolina
Replacing either tank is pretty easy, heres some things that have helped me in the past
Remove the bed. You have to do this to remove the rear tank, it comes out from the top, makes replacing the front one MUCH easier
Do this with 1/8 tank of gas or less, any more and these things get heavy fast!!
You will need fuel line disconnect tools, and be VERY CAREFUL using them. If you damage the little metal internal clip that holds the line on, you will need to replace the whole line.
Id recommend replacing the fuel pumps at the same time, good luck getting the hold down rings out w/o damaging them.
Remove the bed. You have to do this to remove the rear tank, it comes out from the top, makes replacing the front one MUCH easier
Do this with 1/8 tank of gas or less, any more and these things get heavy fast!!
You will need fuel line disconnect tools, and be VERY CAREFUL using them. If you damage the little metal internal clip that holds the line on, you will need to replace the whole line.
Id recommend replacing the fuel pumps at the same time, good luck getting the hold down rings out w/o damaging them.
It was really 10x easier with the bed off... plus you can rattle can the frame while the bed is off.
Never had a hard time getting the retaining ring off...getting it back on is a whole nother story
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FTE Legend
Joined: Sep 2003
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From: NY and VA
Did my 87, you don't have to remove the bed. Along with removal of the filler, I found it fairly easy to drop the rear of the tank first, supported by jack or belly to get to the pump connections. Check vent hose also and replace if needed.
Senior User
Joined: Oct 2010
Posts: 126
Likes: 1
just pointing out a fact, not being mean, but an ESCORT, EXPLORER and F250 in sig. hmmmmmm.. forum is 87-96 ford trucks hmmmmmmmmm. just a fact. n e ways i had the bed off my truck last week. rear tank was dirty inside so i went to pull it out the top, and i couldnt get it. the frame around the tank slopes inward toward tank. there might have been somethign to move to make it come out but i didnt find it. looked easier from bottom.
Senior User
Joined: Oct 2010
Posts: 126
Likes: 1
apparently zxwut? didnt approve of my comment above, i will apologize for it, it wasnt meant to be mean, it was just a point that he said he read the sig and and between the 3 vehicles in his sig, only one has dual tanks and one a truck.
Last edited by megawatt00; Mar 6, 2011 at 12:14 PM. Reason: Comment not necessary
Fleet Mechanic
Joined: Jan 2009
Posts: 1,964
Likes: 2
From: Fort Worth
I'd take the bed off too, but I've done it a couple times before and have a good routine down for it. It'd make removing the fuel pumps much easier. It'd also be the perfect opportunity to replace the bushings between the bed and frame and to identify any issues you can't see from underneath.