Rear - Cab/Chassis

REMOVAL PROCEDURE

TOOLS REQUIRED
J 39765 fuel sender locknut wrench.

CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices.




1. Disconnect the negative battery cable.
2. Drain the fuel from the tank.
3. Raise the vehicle.
4. Remove the fuel tank off-road shield, if equipped.




5. Loosen the filler neck hose clamp at the fuel tank and disconnect the fuel tank filler neck from the fuel tank.




6. Support the fuel tank and remove the tank straps and insulator strips, if equipped.




7. Lower the fuel tank.
8. Disconnect the fuel feed and vapor hoses.
9. Disconnect the electrical connections at the sender.




10. Remove the fuel sender assembly and seal ring, using tool J 39765. Discard the old seal ring.

INSTALLATION PROCEDURE




1. Install the new seal ring and reinstall the sender using tool J 39765.
2. Raise the tank slightly and reconnect the fuel feed and vapor hoses and the electrical connections at the sender.




3. Raise the fuel tank fully.
4. Install the fuel tank straps and fastening hardware.

IMPORTANT: When removing or replacing the fuel tank, the fuel tank support fasteners should never be reused. Always use new fasteners when installing the fuel tank.




5. Reinstall the fuel tank filler neck to the tank. Tighten the clamp.

NOTE:
^ Refer to Fuel Tank Strap Nuts Notice in Cautions and Notices.
^ Refer to Fastener Notice in Cautions and Notices.




6. Install the fuel tank brackets with insulator strips in place.

Tighten
Tighten the strap bolts to 35 N.m (47 lb ft).




7. Install the fuel tank off-road shield, if equipped.

NOTE: Refer to Fastener Notice in Cautions and Notices.

Tighten
Tighten the fuel tank shield fastening hardware to 74 N.m (102 lb ft).

8. Replenish the fuel in the tank. Reinstall the fuel tank filler cap.
9. Reconnect the negative battery cable. If a memory retention device was not used, please reset (to the extent possible) all devices that lost their memory after the battery was disconnected.
10. Check for fuel leaks.
10.1. Turn ON the ignition switch for 2 seconds.
10.2. Turn OFF the ignition switch for 10 seconds.
10.3. Again, turn the ignition switch to the ON position.
10.4. Check for fuel leaks.