Frame-Mounted Tank - 40 Gallon

AFT AXLE FRAME-MOUNTED TANK - 40 GALLON





Removal
1. Drain the fuel into a suitable container by siphoning through the fuel hose at the fuel pump-to-fuel tube connection.
2. Raise the rear of the vehicle.
3. To avoid electrical sparking at the tank, disconnect the ground cable on the vehicle battery.

4. Loosen the clamps on the fuel filler hose and vent hose at the fuel filler pipe assembly.
Disconnect the hoses from the pipe assembly.
5. Disconnect the fuel lines, supply and return, at the front fuel tank support; NOT at the fuel sender.
6. Disconnect the vapor hose at the vapor tube.
Remove clipped vapor hose (6.9L Diesel only).

7. Support the fuel tank in position, and loosen the strap attachment nut (at the rear) that attaches the tank strap to the upper support.
Disconnect the bolt that attaches the tank strap to the front crossmember (pivot strap to the rear of the vehicle).
Lower the tank enough to gain access to the fuel gauge.
Disconnect the fuel gauge sending unit wire at the fuel tank.

8. Lower the fuel tank and remove it from underneath the vehicle.
9. If the fuel gauge sending unit is to be removed from the tank, disconnect the supply, return and auxiliary power take off lines from the fuel gauge sending unit.
Remove six bolts (1/4 inch-20).
Tighten to 13.5 - 17.5 Nm (10 - 13 ft.lb).
Using care, remove fuel sender avoiding damage to the float and filter; also remove and save fuel sender gasket.

10. If the upper support or the rear reinforcement is to be removed, remove nut (hold bolt) that attaches the rear reinforcement and the upper support to the frame rear crossmember.
11. Remove nut that attaches the upper support to the front crossmember and remove the support.
12. If the rear reinforcement is to be removed, remove bolt (weld nut) that attaches the reinforcement to the frame siderail.


Installation
1. If rear reinforcement was removed, install new bolt (weld nut) attaching reinforcement to frame siderail.
2. Attach nut that retains the upper support to the front crossmember.
3. If upper support or the rear reinforcement was removed, attach the hold bolt that retained the rear reinforcement and the upper support to the frame rear crossmember.
4. If the fuel gauge sending unit was removed, scrape away all the old gasket material from the unit mounting surface on the fuel tank.
Using a new gasket, position the fuel gauge sending unit to the fuel tank and secure with the retaining ring.
Retighten the six retaining bolts to 13.5 - 17.5 Nm (10 - 13 ft.lb.).
Connect the fuel gauge sending unit wire.

5. Raise the fuel tank high enough to connect the vapor hose to the vapor tube. Support tank in position and tighten the strap attachment nut (at the rear) that attaches the tank strap to the front crossmember.
6. Attach the fuel filler hose and vent hose at the pipe assembly and tighten the clamps.
7. Connect the vehicle battery ground cable.