Caution: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable.
2. Use a hand operated pump device in order to remove the fuel through the filler neck.

If the pump is equipped, make sure to hook up the static ground wire to a metal part of the gas tank before you begin.

1. Raise vehicle. Refer to

   Notice: When jacking or lifting a vehicle, do not allow the lift pads to contact any of the following parts:

   •	The catalytic converter

   •	The brake lines

   •	The brake cables

   •	The fuel lines

   •	The accelerator cables

   •	The transmission shift cables

   Lift pad contact may damage the parts. Lift pad contact may cause unsatisfactory vehicle performance.
   .
2. Loosen the filler neck hose clamp at the fuel tank.
3. Disconnect the fuel tank filler neck from the fuel tank.
4. Support the fuel tank.



5. Remove the tank straps and fuel tank shield.
6. Lower the fuel tank.
7. Remove the fuel sender shield from the top of the fuel sender.
8. Disconnect the fuel and vapor hoses and the electrical connections at the sender.



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

1. Install a new seal ring.

Notice: Do not fold or twist the strainer when installing the sending unit. This action restricts fuel flow.

2. Reinstall sender using tool J 39765 .
3. Install the fuel tank bottom shield with insulator strips in place.
4. Raise the tank under the vehicle to allow reconnection of hoses and electrical connections.
5. Reconnect the fuel and vapor hoses and the electrical connections at the sender.

Ensure the ground strap is also reinstalled to the body.

6. Install the fuel sender shield on top of the fuel tank with insulator strips in place.
7. Raise the tank fully.
8. Reinstall the fuel tank filler neck to the tank.




Notice: Tighten the strap fasteners by steps, alternating between the fasteners, until the specified torque is reached. A failure to tighten the strap fasteners as specified will cause the bottom of the tank to flex upward. This will result in the fuel gauge indicating that there is fuel remaining in the tank when the tank is empty.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

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.

9. Install the fuel tank brackets with insulator strips in place.
10. Loosely assemble the inboard bolts and spacers through the fuel tank brackets to the frame mounted weld nuts.
11. Loosely assemble the outboard bolts, washers, spacers and jamb nuts through the fuel tank brackets to the frame mounted jamb nuts.
12. Tighten the inboard strap bolts first.

Tighten
Tighten the inboard strap bolts to 35 N·m(26 lb ft).

13. Tighten the outboard strap bolts next.

Tighten
Tighten the outboard strap bolts to 9 N·m(80 lb in).

14. Tighten the jam nuts against the side rail (outboard) last.

Tighten
Tighten the jam nuts to 35 N·m(26 lb ft).

15. Lower the vehicle.
16. Replenish fuel.
17. Reinstall fuel tank filler cap.
18. 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.

19. Check for leaks.