Fuel Tank Removal

Ive done quite a bit of searching and still haven't found more then a standard procedure for removing the tank on my 2003 extra cab trd. Anyone on here know where to find a working fsm or know of a write up on tank removal? The tank has to be removed unfortunately. Not for a fuel pump. I was bit by the rusty frame bug and am in the process of cutting and welding and cutting and welding. Thanks guys.

 

Might be worth it to just remove the bed if you haven't already. Might be easier to get the tank off.

 

The bed comes off real easy. I vote get that thing out of the way.

 

I removed the tank on my 2000 extended cab without removing the bed. It's pretty straight forward, only thing you really have to be careful with is the electrical plug. If you drop the tank (and it has alot of fuel) it could pull the pins out. I would recommend having the least amount of fuel inside if possible. Wear safety glasses because crud will want to fall in your eyes. Loosen the filler hose and vent tube. Be careful not to let these drag on dirty surfaces, essentially putting crud into your gas once you re install. I just put tape on them once they were off. You can remove the skid plate first, if you look closely the front middle bolt holds the tank, while the other two hold the skid and the tank. Once the skid is off, support the tank with a jack, pull the rear pin, and remove front bolt. Next lowe the tank carefully. Here is where you need to be careful. The fuel can slosh to one side or the other, making the tank unbalanced and wanting to tip off the jack. 2 jack stands can help support one end, or a friend. Lowe the tank a little, keeping an eye on wire tension of the plug. Look at the plug, possibly with a mirror to find the detent. Stick your arm in there blindly and unhook plug. It might be stuck on there, so be patient. Once unhooked, just lower it down.
It's really not too bad. After the truck, the 4runner was a breeze.
Install in reverse order.
Have fun!

 

First hand experience is always handy. Thanks guys. I was gonna remove the bed but I have my canopy on as well and figured a little extra work under would prevent from having to reseal and mount the topper. Any special tools for the fuel lines? I have fuel line wrenches but I know some use that special quick lock fitting and can't really see to tell whether it is that style?

 

2 rubber hoses have 1 like clip on each side which can be held open with pliers and there's a larger hose that has a nut on both ends so you'll 2 14mm open end wrenches I believe . The hoses and you fuel pump harness won't stretch very far just remember that . Also there's 1 pin holding the tank strap on just need a punch and hammer

 

Here's a pic of the top of the tank and connector when I was getting the fuel pump.The fuel pressure hard line is 19mm/14mm and use a 14mm line wrench for the smaller b nut or it will/can strip.

My electrical plug was tight and hard to get off after 20 years even with access from above.The push in tab for it is towards the drive shaft.
This is on a 98.

 

HIs is a '03 so it most likely has the pressure connectors, not the 19/14 combo

 

Good info ....Do you happen to know what year they changed?

 

Definitely have the pressure connectors. Luckily was able to jimmy rig a removal tool. Got it out. Seems like they added quite a bit of evap stuff between 98 and 03. 6 hose including the send and return fuel lines and a couple vents. Got it out after some frustration. Not terrible with the entire rear end tore out. I found the rust in the process of lifting so leafs, shocks, axle and driveline are out.

 

Anyone with more info or pics on these pressure connectors and tools used?

I was taking the fuel pump out of 98 in the pics above to send to Texas where I have a 01 with supposed bad fuel pump that a friend is changing for me. I also have a 00 and it's the same as the 98 and wonder which connectors 01's have. I'm supposed to fly down there Monday and drive it back.

Any help or any one change one on a 01?

 

You can get a pack of A/C line, Fuel line connector tools at a parts house pretty cheap. Had mine for years so I can't say exact price.

They are little 360 degree plastic slides with a slit to go around the line, then you push them in to release the lock.

remember though, plastic gets old and brittle. Sometimes they still break or mangle enough where they won't hold pressure.

When they are this old it prob. pays to change it (the lock) and not worry about the fuel line popping off when going down the road.

 

Thanks! I just found out that 01's still have the old school 14/19mm b nuts for the fuel line so they changed in 02 or 03. Friend I bought it off of just changed the fuel pump with the one I sent him and that was the problem. Fired right up and running like a champ again now. Sitting with little to no fuel for over a year killed the pump.

Flying down to Dallas Monday morning to drive it back to Oklahoma to swap the body out. A 01 TRD 5sp ,210k miles with a mint cond rust free Texas frame that was wrecked into some trees when he fell asleep at the wheel.I sent him a good rear window and pass mirror to put on for the drive home as those were trashed.

 

hmmmm...


can i assume that the reinstallation of fuel tank to be major pita for the one man army

 

You don't have to assume. It sucks doing it by yourself.

 

yes, i've been trying to get some quotes from the professionals with all the tools and skillset because i am bound to serious mess something up leaving me ending up having my truck sit disabled indefinitely left to age and possibly rot rot rot

 

Can anyone confirm that the top right tube in the photo is the vent line?

Thanks

 

Yep

 

Thanks. Do you know if its 1/4 inch hose?