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Unread 02-11-2007, 04:45 PM   #1
Grape Ape
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Gas tank access modification

I have been having trouble with my gas tank. I replaced a fuel pump a while back and it has leaked every time I run it. I have fought with it, I have taken the tank down 6 times, extended the hoses so that it will be easier to hook up still I get it all put back and it leaks fuel. I finally decided to mod my jeep to make it easier to work on the fuel pump and hoses without having to remove the tank.

I started by removing the gas tank. Once it was out I cut a section of the floor out approx 29" by 7". I made sure to leave the seat belt mount alone. I still put my seat in and haul people on occasion and did not want to mess it up in anyway so I cut behind its mount.


After that using 3" wide 1/8" thick flat steel I made a base to mount the cut out piece to. I drilled and tapped the pieces so that if necessary I can remove the bolts and slide the metal out giving me more room, without having to mess with nuts and washers on the bottom. I went to tractor supply to get my hardware and steel. The steel was expensive and all they had in 1/4" x 20 bolts/screws etc that were 3/4" long were grade 8 so I had to pay 3.88 for a lb of bolts instead of 1.98 for grade 2 but hey I was going to do it so I paid the price. Total material cost was approx $31.00. I made the pieces a hair shorter than the opening so they can be removed from on top




I then put the piece I cut out back in so I could drill and tap everything without worrying about drilling in to my tank. I found that the support piece welded to the bottom of the floor was in the way. I cut it off, yet left the bent part to help with strength.



I then put the piece I cut out back in so I could drill and tap everything without worrying about drilling in to my tank. This is also what it will look like when all is done.


I then took the cover back off and put the tank back. I hooked up all the electrical and hoses, filled her up and started it and found my leak. I was being way to careful before when tightening the hose clamps down and it was leaking around them. I cranked them down, leak stopped I am happy. Here is a pic of the top of the tank with the cover metal off. As I said before if I need more room to take the pump out I can remove both pieces of metal from above without any problems.


While I had the tank out I noticed my differential plug was leaking and figured I would check the level and add since I had the room. In the process of getting the plug out it broke and one part dropped in the diff other part out. So I had to remove the diff cover. I drained it and cleaned it, put the cover with a new gasket back on. I went to Advance, Autozone, O-reilly, and Napa, none carry the plug. I ended up using a 1" plug designed for a boat. I need my Jeep tomorrow morning and had to have it back together and running before I can swing by the dealer. I will replace it with the proper part but until then the boat plug works wonders.


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Last edited by Grape Ape; 08-21-2008 at 07:16 PM..
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Unread 02-11-2007, 05:14 PM   #2
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tank access was a great idea... looks like you really thoght that out and did a great job.

as for your diff plug... i'd rethink that one. that would easily get caught on something while offroading... not to mention stupid vandels.....

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Unread 02-11-2007, 05:28 PM   #3
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I have to be in Oakridge TN tomorrow morning and that was all I could find the original diff plug was tore apart trying to get it out. I am going to either go to the dealer and get a plug, get a new cover with a screw in plug, or weld a large nut to the cover and put a bolt in it. That boat plug is only to hold fluid in for the next few days until I decide which route I am going to follow. I will probably get the correct plug tomorrow. But in a pinch the boat plug will get me down the road.

I am going to get me some rubber gasket material and make a gasket for the tank cover. I thought of silicone but it is way to cold out for it to work good, so I am going to wait until it gets warmer. I am just glad to have it stop leaking gas.
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EVERYBODY is pro-gun, some just don't know it. When an anti-gun person is in trouble, the first thing they do is call 911 and demand that they send somebody with a gun!

We've idiot proofed the world... now its full of idiots. - Spiritof76

You will truly be the same today as you will be five years from now, except for two things, the people you meet and the books you read. Charles E. Jones

I think I'll add some memorable quotes. blah blah blah..... FPKites

Trying to understand some people, is like trying to pick up a turd by the clean side.
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Unread 02-11-2007, 06:28 PM   #4
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i'd just go with a diff cover that has a thread in drain plug. if i still had mine laying around i'd send it to you for free but i tossed it when i threw out my dana 35.
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Unread 02-11-2007, 06:35 PM   #5
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Great write up on the access, I can see that being very useful. as for the diff cover it begs the question, what lazy moron came up with that idea down at DC? I hope he was fired, they all leak. should be a recall LOL
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Unread 02-11-2007, 06:36 PM   #6
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Quote:
Originally Posted by Grape Ape
I have to be in Oakridge TN tomorrow morning and that was all I could find the original diff plug was tore apart trying to get it out. I am going to either go to the dealer and get a plug, get a new cover with a screw in plug, or weld a large nut to the cover and put a bolt in it. That boat plug is only to hold fluid in for the next few days until I decide which route I am going to follow. I will probably get the correct plug tomorrow. But in a pinch the boat plug will get me down the road.

I am going to get me some rubber gasket material and make a gasket for the tank cover. I thought of silicone but it is way to cold out for it to work good, so I am going to wait until it gets warmer. I am just glad to have it stop leaking gas.
Auto Zone sells a plug that would prolly work a little better. It is the same theory as that boat plug but you have to use a wrench to tighten it up so it would offer a better seal and is not so easy to be opened. They are made to replace stripped out oil pan drain holes and seem to hold up fairly well, and they got several sizes. They are not re-useable though. Once you open it back up that thing is supposed to be replaced.
Maybe this would help you out...
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Unread 02-12-2007, 09:39 AM   #7
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that is a smart idea....thanks!!
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Unread 02-13-2007, 06:38 AM   #8
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The plugs are just plumbing plugs. Lowes, Home Despot, a good hardware store would have one you could use. It will have an external square drive, not an inset one.
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Unread 02-13-2007, 06:48 AM   #9
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That's funny, I had to do that last night to replace my pump! There was no way I was going to try to drop the 18 year old tank with a large snowstorm only hours away. I used the mighty Dremel tool and cutoff wheels, ( only 6 of them! ) , to cut my opening. I made mine around 8x10, just enough to get in there and get access to the lockring holding the pump in. I will soon be sporting a nice .090 aluminum access panel as soon as I fab one.
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Unread 02-13-2007, 08:42 AM   #10
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Quote:
Originally Posted by EABiker
That's funny, I had to do that last night to replace my pump! There was no way I was going to try to drop the 18 year old tank with a large snowstorm only hours away. I used the mighty Dremel tool and cutoff wheels, ( only 6 of them! ) , to cut my opening. I made mine around 8x10, just enough to get in there and get access to the lockring holding the pump in. I will soon be sporting a nice .090 aluminum access panel as soon as I fab one.
As they say necessity is the mother of invention.

That is the reason I thought this up, twice now I have had to throw a tarp down and then some cardboard, just to keep dry and keep the ground from freezing me as I dropped the tank in 10-12 inches of snow. Then put the tank back and fired up the jeep only to find the plug is bad or the thing is leaking and have to drop it again. This is the only route to go.
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EVERYBODY is pro-gun, some just don't know it. When an anti-gun person is in trouble, the first thing they do is call 911 and demand that they send somebody with a gun!

We've idiot proofed the world... now its full of idiots. - Spiritof76

You will truly be the same today as you will be five years from now, except for two things, the people you meet and the books you read. Charles E. Jones

I think I'll add some memorable quotes. blah blah blah..... FPKites

Trying to understand some people, is like trying to pick up a turd by the clean side.
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Unread 06-04-2007, 09:54 PM   #11
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What kind of tubing can I use for the connections from the tank to the filler? The old ones got torn up a bit when removing the tank. Aside from that I think I've got everything covered...

Actually, I got the patch that said "Gas Tank" on it but turns out its for metal gas tanks. Will this work on my plastic one or do I need to go switch it out for plastic? Included are the epoxy, patch (nylon cloth), sand paper, and a brush.
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Unread 06-04-2007, 10:02 PM   #12
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IIRC it is 3/8 fuel line. I think you actually posted this in the wrong thread you should have posted it in your gas tanks problem thread.
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The Final Salute


EVERYBODY is pro-gun, some just don't know it. When an anti-gun person is in trouble, the first thing they do is call 911 and demand that they send somebody with a gun!

We've idiot proofed the world... now its full of idiots. - Spiritof76

You will truly be the same today as you will be five years from now, except for two things, the people you meet and the books you read. Charles E. Jones

I think I'll add some memorable quotes. blah blah blah..... FPKites

Trying to understand some people, is like trying to pick up a turd by the clean side.
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Unread 02-21-2010, 10:35 AM   #13
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This is awesome!
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Unread 02-15-2011, 02:33 PM   #14
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Wow, this is brilliant. Looks like I have to replace my fuel pump. So, I may just try this technique to save me from having to drop the tank. But what about the sparks from the dremel cutting wheel???
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Unread 02-15-2011, 06:31 PM   #15
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This procedure should be a sticky.
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