how to replace a gas tank

[chrisl757]

here are the vitals
96 XJ 4wd. 150K miles.

the gas tank and brackets are rusted out. If I put in more than a half tank of gas in, I get a strong odor. I can't see and leaks, but the smell only happens when I get more than a half tank of gas in.

Can this job be done by one person? and are there any issues to worry about? I read online that you might have to drop the rear end....anyone know for sure on a 96 if you need to do that? If that's the case, I'm taking it to a shop.

Also, the replacement tank is around 150-170. Is there anywhere to get a better deal?

One last thing....it looks like I will have to pull the fuel pump out...is there a filter or something that I should change out now while it's all taken apart?

[MagicRat]

My XJ has the same problem.

Yes, this is a one-person job, and is easy..... in fact, easier than removing the tank on many other cars. Axle removal is not required.

You will need a medium or large sized floor jack, two jackstands, wrenches, sockets, and maybe, a hammer and a drift or blunt chisel. Make sure the tank is virtually empty.

Jack up the rear of the jack and support it using jackstands on the rear axle... not too high. Use blocks on the front wheels so it will not roll.

If you have the rare steel skid plate covering the tank, you have to unbolt this first, 6 bolts total, 3 per side.

Next, place the jack under the center of the tank and raise it until it contacts the underside of the tank. Then, unscrew the two retaining nuts at the front of the tank that hold the straps on, and remove the straps. You may have to soak the nuts in penetrating lube first., if they are rusty.

Remove the clamps that hold the filler pipe on, and loosen the pipe. Remove the fuel pump sender unit wiring and fuel lines which should be at the front of the tank. Carefully lower the tank and roll it out.

Next, you will have to remove the sender unit, On all jeeps I have seen, this is held on by a rotating lock-ring. You will see 3 metal tabs. Tap in the taps gently with the hammer and drift, to get the lock-ring to turn in a counter-clockwise direction. About a quarter-turn should remove the ring.

If the sender unit and gasket are good, you can transfer them to the new tank. But I think it would be a VERY good idea to install a new fuel pump and gasket right now, unless you have already changed the pump recently. Pumps do not last forever.... if it is still original, its life expectancy is pretty limited.

Then, reinstallation is the reverse of the disassembly procedure. When installing the straps, do not go crazy on tightening them up. You want the straps snug, but don't overtorque them

Drain the remaining gas out of the old tank before throwing it out. If the old gas looks clean, reuse it in a lawnmower or something. But it may be dirty/rusty, if so, dispose of it safely, but don't use it in an engine.

Obviously, you are working around a tank full of explosive fuel vapors, so this means no smoking, no grinding, no sparks, no torches and no heat of any kind, when doing this job.

Price? Rockauto.com sells tanks with a new lock-ring and gasket for $98 plus shipping. With shipping included, the price may be approaching $150, but its worth getting a quote from them.

Good luck!

[chrisl757]

thanks for the excellent summary here.

I am going to order from the site you mention above.

this is a pretty nice description of the job. Will keep you posted once parts come in.

[fredjacksonsan]

Moving this to the "How To" Cherokee section. Nice post, Rat.