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.