Gas Tank R&R - How Difficult?

[Longs]

I apparently have a fuel leak somewhere on the top of my gas tank - not enough to reach the ground, but enough to make the sides of the tank and the skid plate wet, and create a nice smell.

I pulled the left rear wheel, and of course with the frame and the skid plate, you can barely see anything. I'm assuming that the leak is coming from the area of the three fuel lines that exit the tank - it's not from the inlet, and I don't believe it's from the vapor line.

How difficult is it to remove the skid plate and lower the tank? Will I need any special parts or tools? Is it necessary to replace the tank straps or bolt, or is it possible to reuse everything?

Thanks in advance.

Longs

 

[Longs]

Getting Worse, Need Help!

Gas flow's getting a little heavier. I'm trying to get the tank as near empty as possible before I try and fix the problem. Anyone have any input?

 

[Stephen S]

I've never dropped the tank on my Explorer, but I had to do it twice in my 87 Ranger to replace the in tank fuel pump and gas guage float. It's not too hard, but it does help if the tank is nearly empty as you say you are trying to do. The tank straps and bolts can be reused, no problem there. Just have someone help you (or a hydraulic jack and some wood if you are alone) with lowering the tank so as it starts to come down, you can slowly lower it and peek over it to make sure you don't stretch any of the lines or filler tube too much. Just remember where you took each bolt from and you'll be fine. Good luck!

 

[jemail]

I just dropped the one on my '91 and there were only 5 or 6 large bolts and 3 or 4 small bolts. It took about 3 hours with a ratchet and socket.

 

[Longs]

Repairs Complete

I had about 14 hours in the job, between running for parts and the actual repairs. A hole rusted into the fuel outlet that's part of the pump assembly. Every bolt was rusty, so I had to use a lot of penetrating oil and repeated loosening and tightening to get them out. The quick disconnects on the top of the fuel tank were also rusty, so I had to shoot a lot of penetrating oil in and work the connectors with a screw driver before the quick disconnects could release.

I had to purchase the entire fuel pump assembly, which included the sending unit and the mounting - $81.00 at Murray's Auto Parts, $169.00 if I purchased it from
Ford. I had to purchase the locking ring from Ford for $10.00 and the quick disconnect tool - about $10.00. I did the job alone with the floor jack and plywood to lower the skid plate and the tank - I had the tank almost empty. Everything got a good coating of antisieze going back together.

This is definitely a job that a shop earns its money on, but I would have hated to be in for $180 in parts plus the labor. I hope that I never have to drop the tank again!

 

[Stephen S]

I'm glad to hear that you were able to get the problem fixed. Thanks for telling us about the details of the job. They may prove to be helpful if some one else ever has this problem.