Aft of Axle Fuel Tank
AFT-OF-AXLE FUEL TANK
Removal
1. Raise the rear of the vehicle.
2. To avoid electrical sparking at the tank, disconnect battery ground cable. Then disconnect the fuel delivery module connector (FDM) near the fuel tank.
3. Using Rotunda 034-00001 Fuel Storage Tanker or equivalent, drain fuel tank.
Drain both tanks on dual tank vehicles.
4. Disconnect the fuel line push-connect fittings at the FDM.
5. Loosen the clamp on the fuel filler pipe.
Disconnect the filler pipe hose by pulling along the rubber inner tube from the tank filler neck.
6. If removing the metal-type tank, support the tank and remove the bolts attaching the tank supports to the frame.
Carefully lower the tank and disconnect the vent tube(s) from the vapor emission control valve in the top of the tank.
Finish removing the filler pipe and filler pipe vent hose if not possible in Step 5.
Remove the tank from under the vehicle.
7. If removing the plastic-type tank, support the tank and remove the bolts attaching the combination skid plate and tank support to the frame.
Carefully lower the tank and disconnect the vent tube(s) from the vapor emission control valve in the top of the tank.
Complete removing the filler pipe if not possible in Step 5.
Remove the skid plate and tank from under the vehicle.
Disassemble the skid plate from the tank.
8. If necessary, remove retaining ring with Fuel Tank Sender Wrench D84P-9275-A or equivalent then remove FDM and gasket. Fuel gauge unit may be separated from fuel pump and reservoir assembly.
Installation
1. If the tank or vapor emission control valve is being replaced, follow the installation procedures in the illustrations under Emission Control Systems.
Install new support strap insulation as required.
2. If removed, install new gasket and FDM.
Make sure FDM tabs are seated in slots in gas tank and that retainer ring is tightened until tabs are positioned between detente and stop on tank.
Use Fuel Tank Sender Wrench D84P-9275-A or equivalent.
3. If installing the plastic type tank, assemble the skid plate and support straps to the tank.
4. Raise the tank skid plate and support assembly and attach the vent hose(s) to the vapor emission control valve.
5. Start the tank neck into the hose.
6. Position the tank assembly filler against the top straps of the frame.
Install the attaching bolts and nuts using thread adhesive (such as Locktite).
Tighten the attaching bolts and nuts to 37 - 50 Nm (27 - 37 ft.lb.).
NOTE: The plastic tank attaching bolts and nuts do not utilize thread adhesive.
Tighten these bolts and nuts to 34 - 47 Nm (25 - 35 ft.lb.).
7. Insert the rubber inner hose inside the tank filler neck and connect the filler pipe hose.
Tighten the clamps to 3 - 4 Nm (25 - 35 in.lb.).
8. Connect the FDM electrical connector.
9. Connect the fuel lines at the FDM. Install the drain plug, if so equipped.
10. Connect the vehicle battery ground cable removed in Removal Step 2.
11. Fill the tank and check all connections for leaks.
12. Lower the vehicle.