Removal Procedure
- Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
- Drain the fuel tank. Refer to Fuel Tank Draining .
- Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
- Remove the exhaust system. Refer to Exhaust System Replacement .
- Remove the propeller shaft. Refer to Propeller Shaft Replacement .
- Remove the right rear wheel. Refer to Tire and Wheel Removal and Installation .
- Disconnect the evaporative emission (EVAP) hose (1), by squeezing both sides of the hose (as indicated in the illustration) and pulling it toward the rear of the vehicle.
- Release the worm drive hose clamp (1) and remove the filler tube (2).
- Disconnect the fuel feed pipe (1) and EVAP emission pipe (2). Refer to Plastic Collar Quick Connect Fitting Service .
- Disconnect the fuel tank electrical connector (1).
- Support the rear frame assembly using a suitable tool.
- Remove the rear frame to chassis retaining bolts (1) and (2) and discard.
- Support the rear frame using the frame support tool EN-48536 Engine Support Tool (Engine Lower 65 MM Kit) (1). Repeat for the opposite side.
- Support the rear frame using the frame support tool EN-48536 Engine Support Tool (Engine Lower 65 MM Kit) (1). Repeat for the opposite side.
- Lower the rear frame approximately 50 millimeters (2 in) (A) at the rear mounting surface between the rear frame and the chassis.
- Remove the fuel tank heat shield. Refer to Fuel Tank Heat Shield Replacement .
- Disconnect the park brake rear cables from the park brake front actuator cable. Refer to Parking Brake Actuator Cable Replacement .
- Disconnect the EVAP emission pipe (2) from the EVAP emission canister (3). Refer to Plastic Collar Quick Connect Fitting Service .
- With the aid of an assistant support the fuel tank
- Remove the fuel tank strap to chassis retaining bolts (1).
- Remove the fuel tank straps.
- With the aid of an assistant, remove the fuel tank from the vehicle.
- Remove the following components from the fuel tank if the fuel tank is to be replaced.
- The primary fuel tank module-Refer to Primary Fuel Tank Module Replacement .
- The secondary fuel tank module-Refer to Secondary Fuel Tank Module Replacement .
WARNING:
Refer to Gasoline/Gasoline Vapors Warning .
WARNING:
Refer to Safety Glasses Warning .
NOTE:
When lowering the rear frame use care not to over extend the rear brake hoses.
NOTE:
Do not damage the fuel tank wiring harness or fuel tank hoses.