How hard is it to put a new rear tank in my 96 f250 long box 7.3 ? Do I need to buy a new sending unit or just a new tank and put the old sending unit in it? Thanks

 

The worst part about changing the tank is rehooking the fuel lines back up. A lot of people pull the box off for easy access. I did it with the box on but I I clipped the merely fuel lines closest to the tank, plus I have real long skinny arms which helped. I reused my sending unit. I used a jack to lower and lift my tank in place. Some use ratchet straps. I also had to drop my hidden hitch as well.

 

Should I put the shrouds around the tank again? Or leave them off so it does not get holes in it ha

 

Reconnecting the lines is SUPER easy. DISconnecting them is slightly difficult, but there's a tool to trip the quick-releases. They're two different sized lines (so you can't get them mixed up), so techincally you need the two different size tools, but I cheated and used the smaller size tool on both lines.

To disconnect them, take off one skid plate (or strap, if 2WD), put a ratchet or cam strap in its place, then do the same on the other side. Then let out the strap to lower the tank about half way. That'll give you plenty of room to get the tool in there and disconnect the lines. Same trick on installation - raise about halfway with the straps, reach in and connect (no tool needed, they just snap in), then raise into position.

The wires do NOT disconnect right at the "hat". Follow the wires to a connector to the main harness on the frame, and disconnect there.

You'll prob. destroy the lock ring upon removal; new tank should have one (Spectras do). When you pull the hat, don't be surprised to see the pickup strainer (shower head) in pieces, falling apart or totally loose. Replacement is available on Amazon.

If you're replacing because the tank rusted on the bottom, and it's a 4x4, no surprise. STOOOOPID Ford design, to use the skid plates to hold up the tank. Wet icky road crud builds up on the plates, settles wher the edges of the tank sit on the plates, perfect recipe for rust. Fix - get some longer bolts (or studs), four 1" spacers, and some extra washers and nuts. Also buy the straps used in the 2WD applications. Mount the tank using the straps, with the extra bolt/stud length pointing down. Then slip the spacers over the bolts/studs, add washers, THEN mount the skid plates with the extra washers and nuts. This creates a 1" air space between the tank and plates, no direct contact of all that road crud. Anything that does build up on the plates, you can hose off at the DIY-wash.

DEF re-use the sending unit, don't damage it while it's out. Get on Amazon and price a replacement, if you're in the mood for some sticker shock.