Chrysler Full-Size Trucks 1967-1988 Repair Guide

Tank Assembly

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REMOVAL & INSTALLATION



Pick-Ups
  1. Disconnect the battery ground cable.
  2.  
  3. Remove the fuel tank filler cap.
  4.  
  5. Pump all fuel from the tank into an approved container, then raise and safely support the vehicle.
  6.  
  7. Disconnect the fuel line(s) and wire leads to the gauge unit. Remove the ground strap.
  8.  
  9. Remove the vent hose shield and the hose clamps from the hoses running to the vapor vent tube.
  10.  
  11. Remove the filler tube hose clamps and disconnect the hose from the tank.
  12.  
  13. Place a padded transmission jack under the center of the tank and apply sufficient pressure to just support the tank.
  14.  
  15. Disconnect the two J-bolts and remove the retaining straps at the rear of the tank. Lower the tank from the vehicle. Feed the vent tube hoses (usually 2) and filler tube vent hose through the grommets in the frame as the tank is being lowered. Remove the gas tank sending unit.
  16.  

To install:
  1. Inspect the fuel filter, and if it is clogged or damaged, replace it.
  2.  
  3. Insert a new gasket in the recess of the fuel sending unit and slide the sending unit into the tank. Align the positioning tangs on the sender with those on the tank. Install the lockring and tighten securely.
  4.  
  5. Position the tank on a transmission jack and raise it into place, feeding the vent hoses through the grommets on the way up.
  6.  
  7. Connect the J-bolts and retaining straps, then tighten to 40 inch lbs. (4.5 Nm). Remove the jack.
  8.  
  9. Connect the filler tube and all vent hoses.
  10.  
  11. Connect the fuel line(s), ground strap, and sending unit wire leads.
  12.  
  13. Lower the vehicle.
  14.  
  15. Refill the tank and inspect it for leaks. Connect the battery ground cable.
  16.  

Ramcharger and Trail Duster
  1. Disconnect the battery ground cable.
  2.  
  3. If there is a tank skid plate, remove it.
  4.  
  5. Remove the tank filler cap.
  6.  
  7. Pump or siphon the contents of the tank into a safe container.
  8.  


CAUTION
Siphoning should not be started by mouth! Only fuel-safe pumps should be used.

  1. Raise and safely support the vehicle.
  2.  
  3. Disconnect the fuel line(s) and tank sending unit wire(s). Remove the ground strap or wire.
  4.  
  5. Remove the hose clamps from the vent dome hose.
  6.  
  7. Remove the filler tube hose clamps. Detach the hoses from the tank.
  8.  
  9. Support the tank with a padded transmission jack.
  10.  
  11. Disconnect the two J-bolts and remove the straps at the rear of the tank.
  12.  
  13. Remove the tank sending unit.
  14.  

To install:
  1. Use a new tank sending unit gasket. Check the filter on the end of the fuel suction tube.
  2.  
  3. Use a new or undamaged tank-to-frame insulator. Raise the tank into position.
  4.  
  5. Connect the J-bolts and retaining straps. Tighten the bolts until about 1 in. (25mm) of threads protrude.
  6.  
  7. Connect the filler tube and all hoses. Tighten the clamps.
  8.  
  9. Connect the fuel line(s), ground strap or wire(s), and tank sending unit wire. Make sure that all fuel line heat shields are in place.
  10.  
  11. Install the skid plate.
  12.  
  13. Lower the vehicle, then connect the negative battery cable.
  14.  

SENDING UNIT



Except Fuel Injection
  1. Disconnect the negative battery cable.
  2.  
  3. Raise and support the vehicle.
  4.  
  5. Remove the fuel tank from the vehicle.
  6.  
  7. Unfasten the sending unit with the proper tool (either spanner wrench or screwdriver), then remove.
  8.  

To install:
  1. Insert a new gasket in the recess of the fuel sending unit and slide the sending unit into the tank. Align the positioning tangs on the sender with those on the tank. Install the lockring or screws and tighten securely.
  2.  
  3. Install the fuel tank on the vehicle.
  4.  
  5. Lower the vehicle, then connect the negative battery cable.
  6.  

Fuel Injection

To remove the sending unit on a fuel injected vehicle, refer to the fuel pump procedure earlier in this section.

 
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