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Old 04-09-2010, 08:08 AM   #2
das2123
Tuning Neons since '97
 
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Re: 96 Neon Gas Tank Support Question

This should help you out...

- Back vehicle up onto ramps, set parking brake, shut vehicle off. (block front wheels for added safety if you wish)
- Open hood, & disconnect the negative battery terminal
- Put on gloves & safety goggles at this point and go under the rear of the car
- You will see over the passenger side front corner of the gas tank, a shield which is held on by 3 small bolts. Remove 2 using your 8mm socket, and the larger one using your 10mm socket.
- Under the shield is 1 connector, and 2 gas lines. Pinch the clips with your fingers on the gas lines (one blue one green you may want to mark them at this time) and remove them from the in tank pump. Slide the red lock on the electrical connector to the right, then remove it.
- Open your gas door at this time, and using your T25 torx bit, or driver remove the 4 screws around the gas filler orifice which will release the filler neck (you do this so you don't break the filler neck when trying to slide the filler neck off the rubber hose mating it to the gas tank.)
- Place your hydraulic jack directly under the center of the gas tank, eyeball it straight and put your piece of wood on top of the jack length-wise with the car to support the tank, raise the jack to touch the bottom of the tank.
- Using your 13mm (or 15mm on plastic tank cars I believe) remove the 2 bolts which hold on your straps and allow the straps to hang down.
- Slowly lower the jack until the tank is down a couple inches, and stop. Now with your flathead screw driver losen the clamp closest to the filler neck on the rubber coupler. Once it's loose enough, slide it out of the way and finess the filler neck, and the rubber coupler apart so you can drop the tank. (stick screw driver between rubber and filler neck, squirt in some PB blaster to make this process faster.)
- There is a T fitting on the rear of the gas tank, unhook both lines connecting to it so the gas tank is no longer connected to the vehicle at all.
- Proceed to lower the gas tank all the way, and slide it carefully off the jack onto the ground, then out from under the car. Remove the filler neck from the vehicle as well at this point, because it's probably rusting and it would be a great time to hit it with some rust inhibitor or paint.
- Remove the straps from the vehicle by turning them sideways, they come right out easily as long as they aren't rusted to the car.
- Gas tank removal is complete, set aside all of your hardware and don't lose the torx screws or the bolts.
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2003 Dodge SRT-4
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