step by step replacement of a fuel tank and fuel lines

twicepipes

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I own a 1998 2 door Tahoe and noticed the fuel tank was leaking. Looking things over I see the fuel lines are badly rusted. I ordered a tank from rock auto for $110.00 got some fuel lines at the auto part store and was curious if anyone would like to see step by step with photos on the replacement, (this would be my first post on such a thing)
 

twicepipes

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replacement of a fuel tank and fuel lines

Living in Pennsylvania rust is always a problem. When I would fuel up anything over 3/4 the tank leaked. After looking things over the fuel lines were in need of replacing
 

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twicepipes

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replacement of a fuel tank and fuel lines

I prepped and painted the new tank
 

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twicepipes

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replacement of a fuel tank and fuel lines

The next step was to get the truck on jack stands and begin the removal process. I started with the filler neck.
 

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twicepipes

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replacement of a fuel tank and fuel lines

I used my favorite penetrate oil (50/50 tranny fluid and acetone) on the filler neck and used a pick to loosen the hoses. After the hoses are unstuck I used a hose removal tool.
 

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twicepipes

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replacement of a fuel tank and fuel line

The fuel tank strap bolts needed wire wheeled and oiled down. Then get the floor jack and wood blocks under the tank. Remove the two bolts and slowly lower the tank enough to get access to the 3 lines ( 2 are fuel and 1 is the vent ) and the 2 electrical connectors.
 

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twicepipes

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replacement of a fuel tank and fuel lines

Since I was going to replace the fuel lines a chose to cut the 2 fuel lines. If you don't have to replace the fuel lines they will need to be removed from the sending unit with a fuel line tool. Be sure to blow out all the dirt and grime before removal. The connectors have 4 tangs the tool presses against to release the line.
 

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twicepipes

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replacement of a fuel tank and fuel lines

With the tank on the ground its time to remove all the parts. Spray down the vent hoses and filler hose then carefully use a pick around the hoses to free them up. the 2 vent valves had a lot of rust around them so I used a chisel to brake up all the rust. Working the vent valves back and forth I was able to remove them
 

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twicepipes

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replacement of a fuel tank and fuel lines

A little more on the vent valves. I used a pick between the valve and the tank to brake the rust before twisting them back and forth. They have ( I will call it a stainless tension ring and an o ring) Be careful removing them they will brake.
 

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twicepipes

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replacement of a fuel tank and fuel lines

The next thing I did was remove the sending unit and cleaned it up and put a new fuel strainer on. I put new vent lines and new clamps
 

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twicepipes

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replacement of a fuel tank and fuel lines

The 2 fuel lines that come off the sending unit are plastic with a braided cover. I needed the fuel lines to go from plastic to high pressure rubber lines, so I installed barbed fittings from the local auto parts store.
 

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twicepipes

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replacement of a fuel tank and fuel lines

In order to get the barbed fittings into the plastic lines they will need to be heated up. I used a hair dryer. Then place high pressure clamps on the lines.
 

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twicepipes

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replacement of a fuel tank and fuel lines

I removed all the rusted fuel lines and fuel vent lines. The 3 lines to be replaced are 3/8 - 5/16 - 1/4 . Starting from the new fuel filter back using compression fittings for the connections I bent the lines so they would fit in the factory hold down brackets
 

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twicepipes

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replacement of a fuel tank and fuel lines

After the 3 steel lines were run just pass the rear shock I flared them so when the rubber lines were clamped on they could not come off. Next I used a ratchet strap to hold the tank up part way to allow enough room to make the connections
 

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twicepipes

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replacement of a fuel tank and fuel lines

Place the 2 hoses for the filler neck back together ( a dab of oil around the hose helps ) and clean/grind the area where the ground strap goes to the body. Be sure to check all connections, hoses ,clamps, electrical connectors and such before bolting the two 15mm bolts that hold the tank up.
 

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anunez

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Thanks for the pictures. My 99 Hoe quit running as I was driving on a farm rd so I replaced the Fuel Pump and one hose was leaking and I knew it had clicked so took it off and there was no O Ring so I ordered them and I will pick up today, Your pictures show where these O Rings should be located thanks
 
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