How To Replace Fuel Tank 1983-97 Ford Mustang PART 2
Created on: 2010-09-21
As part 2 of a 2-part video, this video will show how to prep and install and a new gas tank in 83-97 Ford Mustangs
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step 1 :Beginning the Repair
- This is Part 2 of a two part video
- Please consult Part 1 for earlier instructions
- Follow the steps outlined in Part 1
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step 2 :Preparing the Tank
- Use a wire brush to clean the fuel sending unit settings
- Unplug the sending unit lines
- Use a hammer and chisel to loosen the lock ring tabs
- Remove the lock rings
- Remove the sending units
- Remove the sending unit grommet
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step 3 :Installing the Sending Units in the New Tank
- Attach the grommet, keeping dirt out of the tank
- Insert the new O-ring for the first sending unit
- Line up the sending unit tabs with the tank slots
- Put in the sending unit
- Attach the lock ring underneath all three tabs
- Use the hammer and chisel to push the lock ring tabs into place
- Insert the new O-ring for the second sending unit
- Line up the sending unit tabs with the tank slots
- Put in the sending unit, making sure the hoses are placed correctly
- Attach the lock ring underneath all three tabs
- Use the hammer and chisel to push the lock ring tabs into place
- Insert the fuel filler neck grommet
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step 4 :Replacing the Fuel Tank Straps
- Hold the first fuel strap
- Use needle nose pliers to remove the rear fuel strap bolt
- Remove the fuel strap
- Repeat for the second strap
- Insert the longer fuel strap on the passenger side
- Insert the rear fuel strap bolt
- Insert the shorter fuel strap on the driver side
- Insert the rear fuel strap bolt
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step 5 :Installing the New Fuel Tank
- Reattach the plastic protector and fuel tank padding
- Position the fuel tank
- Hold the tank in place with a jack
- Feed the hoses through the appropriate clips
- Reattach the electrical connection
- Hold the tank in place
- Position one tank strap
- Hold the strap in place with the jack
- Position the second tank strap
- Tighten the front bolt on the strap held by the jack
- Move the jack to the other strap
- Tighten the front bolt on the second strap
- Finish tightening the bolts
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step 6 :Attaching the Connectors
- Insert the fuel line nylon lock
- Reattach the fuel lines
- Attach the lock clamp
- Drill a hole in the fuel tank weld
- Bolt the tank to the clamp
- Bolt the filler neck in place
- Add fuel to the tank
Tools needed
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13mm Socket
Hammer
Jack Stands
Block of Wood
Flat Blade Screwdriver
8mm Socket
Drill
Chisel
10mm Socket
Ratchet
Wire Brush
Floor Jack
Needle nose pliers
Brought to you by 1AAuto.com, your source for quality replacement parts and the best service on the Internet.
Hi, I'm Mike Green. I'm one of the owners of 1A Auto. I want to help you save time and money repairing or maintaining your vehicle. I'm going to use my 20-plus years experience restoring and repairing cars and trucks like this to show you the correct way to install parts from 1AAuto.com. The right parts installed correctly: that's going to save you time and money. Thank you and enjoy the video.
This is part 2 of reinstalling the tank in this Ford Mustang, and again this repair is the same for most vehicles; it's basically disconnecting the fuel lines and electrical connections to the tank, pulling the tank down, then changing over anything you want to change over or installing new items, and then replacing the tank and here's a look at the tools you will need.
Remember I talked about putting new settings in? You can see this is a little crusty here so what I'm going to do is use a cold chisel and a wire brush and clean up around these, here and here. After that I'll figure out where the lock rings are and I'll show you how to undo the lock rings. This can unplug. Once you clean up here pretty good, you can see the little bend over there and then there's a little tap of metal sticking up right there. You want to take your cold chisel or a screwdriver or something and actually contact this right here. It's good to get all three to try and get it going. Now it's moving pretty well. There's the ring, and there's my sending unit on this one. This just pulls right up, the grommet. Grab that as well as this, on this side.
Put the grommet back on, get the sending unit back in here. What is going on? Obviously I'm trying to get as little dirt in there as possible, hopefully none. Okay our new tank comes with a new lock ring and an O-ring so you want to make sure you put the O-ring down in there. The sending unit does have tabs that line up with slots so you can't really put it in the wrong place. I guess you could but you would really have to force it. Put the sending unit down in there, take the lock ring and make sure it's going underneath all three tabs.
Okay so that one is started. I'll do this one; we'll take the old lock ring off. This sending unit is a little fun, okay, how it goes in, so I'm going to take it all the way out so I can sure you here. Like I said, think about replacing your sending unit when you do this. You're going to put it down in. When you get to here, you want to pull it up and turn it around. This is my rubber gasket. So put the rubber gasket down into its groove and here are the spaces of the tab there. It goes down into that slot. Sometimes it can be challenging to get these down in beyond the ears. Put the lock ring on, get it started, and then it's just like taking them out.
Then we'll do that to the other side. Then we've also taken our grommet over here for where the fuel filter goes in. I've cleaned it up a little bit, and we'll put it back in.
Okay so now we want to get the straps out. Basically, you kind of lift up and then probably get a pair of needle-nose pliers in here and get hold of the bolt here and just pull it out. There are two different straps; you want the longer one on the passenger side. Put it up in there, and then push that in there. Same thing for the other side.
We got a new tank. It's all set in the little plastic protector. I put all the pads I transferred all the pads and duct tape and everything. They just help to reduce noise and vibration so we're ready to put it up in.
Feeding my hoses through their clip over here, hook up this hose, pull these hoses down a little more, looks pretty good, hook up my electrical connection. Next thing I'm going to do is I'm going to hold the tank up; these down here. I'm going to put my jack right under my strap. You don't want to be shy with the jack; you want to jack the strap right up in there, and then get the bolt going. Once you got one side, then you can move the jack over to the other side. Then once you got both of them in then you want to tighten them right up nice and snug. It might help you there too. I got a block of wood right up under the strap to help me with that. Okay now we're going to re-hook up our lines so we're going to put this little lock nylon up in there. Put the line up in, bring the lock down, push that up on, and pull the lock down into it. On this one, put it on the filter, push on it nice and tight and then put this lock right through. This one's all set. Tank's tight, connections are hooked up, and all we have to do, is we need to drill a little hole right here and we're going to drill it right on the outside of the weld here. You can see where the weld is right here; we're going to drill it on the outside so we can bolt that back up and then put our bolts back into the filler neck, the four down below, the three up top. Put some gas in it and we should be all set.
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