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Unread 04-30-2007, 11:12 AM   #1
BIG BUBBA
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1995 YJ Wrangler 
 
Join Date: Apr 2007
Location: Michigan
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removing YJ gas tank

Has anyone done this? Is there anything I should lookout for, or avoid. I need to remove it to install my rear tire carrier/bumper. Any tips would be great.

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Unread 04-30-2007, 11:20 AM   #2
NMjeepersYJ
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Droppin' the tank is a ***** of a job. There are 4 nuts on the back that need to be removed and then three bolts with nuts on top that need to be pulled too. when you pull those seven, the tank will drop... but don't forget, you have 2 fill hoses that will need to be disconnected as well as two rubber fuel lines that connect to the pump, two vent lines, and the electrical sensor. What I did was put some cinder blocks under the tank so it would only drop a couple inches, pull the bolts, and rest the tank on the blocks. Then I disconnected everything on top of the tank. Then pull that monster out and that's that. Getting 'er back in is just as fun Good luck.
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Unread 04-30-2007, 11:24 AM   #3
BIG BUBBA
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tank removal

bolts on top? If you remove the bacl bolts will that allow it to drop enough to get the other three? The fuel lines must connect from the top of the tank because I see a whole lot from the bottom. Does it have a fuel pump in the tank?
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Unread 04-30-2007, 11:27 AM   #4
93YJfalcon
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I disconnected everything then siphoned all gas out - then dropped the tank with a jack under it to lower it slowly.. The jack works well for reinstalling it. Definately get a Haynes manual and follow the directions.
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Unread 04-30-2007, 11:27 AM   #5
NMjeepersYJ
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Quote:
Originally Posted by BIG BUBBA
bolts on top? If you remove the bacl bolts will that allow it to drop enough to get the other three? The fuel lines must connect from the top of the tank because I see a whole lot from the bottom. Does it have a fuel pump in the tank?
Yeah, not on top (sorry, can't think today). Up front. At the front of the tank is a lip where three bolts go through the skid on tank. All the lines are connected on top and the pump is in the tank.



Why do you have to pull the tank to install the carrier???
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Unread 04-30-2007, 11:34 AM   #6
BIG BUBBA
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can I get a Haynes manaul at Auto Zone?
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Unread 04-30-2007, 11:40 AM   #7
93YJfalcon
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Yep.. They're about $12. Money well spent!
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Unread 04-30-2007, 11:46 AM   #8
BIG BUBBA
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tank removal

I need to drop the tank to reach the 2 inside bolt mounts on the back of the bumper. I have one of the Rugged Ridge tire carrier bumpers that looks just like the Smittybuilt. All of the bolts have to go through the back of the frame rail and screw into the back of the bumper. There is no way I can reach the bolts on the inside without dropping the tank. The gas tank is in the way from the top, and the springs from the bottom. I talked to my local 4x4 shop and he said they drop the tank to put that style of bumper on.
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Unread 04-30-2007, 01:21 PM   #9
Slapahoe
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You will want to wash the ender side of your jeep very well first, so when youre removing it, dirt does not contaminate the tank. Specifically where your gas lines reach up to the filler neck.

You best bet is when you remove the tank use two jacks, this will ease the process. On top of the jacks, have a thick peice of plywood to have as a flat surface for the tank to come down on.

My best advise as well is to take off the filler neck and hoses before you start to remove parts. Start by removing the outer neck where your insert a nossle for gas. then remove the two tubes attached to it an the tank, these must be removed anyways because you are dropping the tank. Removing these will give you the oppertunityt o replace the clamps with newer ones, also it will give you a oppertunity to check your filler neck for rust, etc.

After you have the plywood up, apply a bit of pressure with the jacks on the tank untill the jeep lifts up about 1/4" to 1/2", anymore is overkill.

Next remove the bolts and proceed to let the jacks move the tank down. Note that there are two bolts on each side that do not need to be removed. They hold the metals straps stetching on top of the tank. You can remove the tank with the straps on.

Once everything is removed, SLOWLY lower the tank. when you get about half way down, you should be able to put your hand above the tank and start to remove the clamps and electrical harness. A bit of advice would be to use some needle nose vise grips to pinch the gas lines going to the tank, this way it will not spill all over your when removing the lines.

After everything is removed and pushed to the side, proceed to lower the tank and after your finsihed doing what you need to do, installations is reverse of removal.

Good luck
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Unread 04-30-2007, 02:42 PM   #10
Shenandoah
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I would advise running most of the gas out before trying to remove the tank. When you remove the bolts holding the tank to the body slightly lower the skid plate and tank, then cut the filler hoses. It's easier to cut the old hoses than remove them. You need to replace the hoses anyway.

The tank will probably bang on the exhause pipe and you will have to angle it somewhat to clear the pipe. When you do the work you'll see what I'm talking about. I've done it by myself several times, but I would suggest having a buddy to help.
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Unread 04-30-2007, 04:39 PM   #11
Smash209
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I cut my hoses... then found out they are pricey to replace... about $20 plus shipping... i would advice against cutting hoses IF you think yours might be okay. That said... i like having new hoses there anyway.

My gas tank was easy out and in... not nearly as hard as i thought.
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Unread 04-30-2007, 06:48 PM   #12
mean90yj
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anyone ever try and do it with a full tank? lol.
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Unread 04-30-2007, 07:15 PM   #13
jeepyj027
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I've been working all evening to try and get my tank out. It has less than 5 gallons of gas in it. Everything went pretty smooth until I got to the point if dropping the tank to remove the lines on top of it. The rear exhaust mount has been rigged up and there is no way to remove it without taking the tank out, but I can't get the tank out to remove it. So I'm at a stalemate. On the other side of the tank, the necks on the tank for the filler hoses keep hitting the frame and preventing the tank from dropping. Does anyone have any ideas?
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Unread 04-30-2007, 08:00 PM   #14
bayvilleYJ
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I dropped my tank with a lot of gas in it , just put a jack under it and lower it down. If your as unlucky as me , every bolt on it will be rusted and strip.
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Unread 04-30-2007, 08:26 PM   #15
xwildman138x
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mine was a PIA too I ended up having to take off the exhaust to get the darn thing out. Gas sloshing around its easy to loose control of it, busted knuckles, wrench thrown through the back screen door rust in my eyes and ears.......god what a good time it was.
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