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HOW TO REMOVE/INSTALL A FOX MUSTANG GAS TANK, ALL BY YOURSELF!
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Ever try to do it alone, without the help of friends? Especially if there's gas in it? Two words..................IT SUCKS! Recently, I had to replace my sending unit which necessitated pulling the tank. After careful thought, I came up with the idea for a simple cradle made from 2x4's that'll bolt directly to a floor jack. All materials were purchased at Home Depot.
Materials needed:
2 - 8' lengths of 2x4 lumber..........................$4
1 - 3/4" x close pipe nipple...........................$1
1 - 3/4" x 2" bolt, 2 washers, 1 nut.............$1.25
1 - small scrap piece of 3/4" plywood
A couple of dozen 2" coarse drywall screws.
Break out the circular saw (or handsaw) and cut 2 - 36" and 4 - 19" lengths from the 2x4's. Then cut a 12"x12" square section from the scrap piece of plywood. Locate the center of the 12"x12" piece, use a holesaw and drill a 1-1/8" hole. Take the 3/4" x close pipe nipple and tap it into the hole about a 1/4" with a ballpeen hammer. The O.D. of the nipple is about 1-3/16" so it'll tap in snugly. Make sure 1 length of 36" lumber is standing on the narrow side and the other 36" piece is laying down (see pics). Now screw the 4 - 19" pieces to the 36" pieces for vertical supports. Screw the 12"x12" piece to the 2 center 19" pieces and your finished! Below are pics of the backside and closeup of the nipple.
Now, if you have a cheap Costco floor jack, like me, the saddle simply lifts out!
Now, flip the wooden cradle over and insert the nipple into the saddle hole. Install the 3/4" bolt, with 1 washer, up from the bottom. Install the 2nd washer and nut on top and tighten. There's your completed gas tank lifting cradle!
Center the jack and cradle under the tank and jack it up until there is slight pressure on the tank. Now unbolt the tank straps from the front of the tank. Next, release fuel pressure at the schreader valve on the fuel rail. Disconnect the fuel pump and sending unit electrical connector at the center rear of the tank between the tank and rear bumper. Now, remove the vent hose from the metal tube.
Remove the 8mm bolt that holds the filler tube support ring onto the tank.
Now you're ready to disconnect the fuel lines. Have a drain pan and rags at the ready. There WILL be residual fuel that will squirt out of the lines, but not much. Remove the plastic retaining clips on the fuel lines. There are 2 types.
The easy one is on the supply line. It has 2 tangs that you push against and the clip should pop right out. Once the clip is out, give a good yank on the fuel line and it should pop right off. I used some junk fuel lines as examples.
The 2nd type of retainer, on the return line is a bit more difficult. There are tangs on 2 sides also but these need to be pushed in, one at a time and at the same time the small lip on top of the fitting needs to be pryed up. Once the clip is out, give the fuel line a good yank and it should pop out, also.
You can purchase new retaining clips at any auto parts store for around $2. I bought mine at NAPA auto parts. Part # 730-4902. The package contains both types of clips.
Everything is now disconnected. Slowly lower the tank. At the same time you need to wiggle the filler tube out of the side of the tank. Push the tank slightly to the left to aid in wiggling out the filler tube. The tank straps are flexible and will feed out from between the 2x4 vertical supports.
Once the filler tube and straps are clear, lower the tank completely down and roll the jack, along with the cradle and tank out from under the car. To install, reverse the procedure. Installation, is even easier! The cradle makes all the difference in the world!
That's all she wrote! This thing had 3/4 of a tank of gas in it when I did the R&R! The cradle and tank are extremely stable with no wobbling or rocking from side to side! It gives the tank TOTAL support. The best part is, it took me all of 15 minutes and cost a little over $6 to build the cradle! When done, stand it on end and it takes up very little room, or remove the screws and break it down! Cheap, simple, effective and works like a charm!!
This is for a Fox Mustang but one could be easily built for any tank, simply change the dimensions. Or, if you're really ambitious, build one that's adjustable! Food for thought!
