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How to Replace 26 gal Gas Tank 02-08 Dodge Ram 1500

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How to Replace 26 gal Gas Tank 02-08 Dodge Ram 1500

Created on: 2016-08-10

This video will show how to empty the fuel system, clear fuel from the fuel rails, and many more steps to remove the gas tank from the 02-08 Dodge Ram 1500

  1. step 1 :Emptying Fuel from the System
    • Behind the inner wheel well liner on the driver side fender, locate the connector
    • Pry back the red safety with a flat blade screwdriver
    • Lift up the gray latch up all the way, which will separate the terminals
    • Open the fuel door and remove the fuel cap
    • Start the vehicle and crank a few times to run the system out of fuel
  2. step 2 :Disconnecting the Battery
    • Remove the 10mm wrench from the negative terminal of the battery
  3. step 3 :Removing the Air Filter Box
    • Loosen the metal clips
    • Lift the airbox out of its holders
    • Remove the PCV hose
    • Loosen the rear inlet pipe hose clamp
    • Work the pipe off and remove the assembly
    • Lift the airbox up and out of its retainers
  4. step 4 :Removing the Airbox
    • Remove the 10mm bolt behind the alternator
    • Remove the 10mm bolt behind the oil cap
    • Lift the air box to disconnect the air intake temp sensor
    • Remove the airbox
  5. step 5 :Clearing Fuel from the Fuel Rails
    • Remove the cap on the Schrader valve on the passenger side of the fuel rail
    • Place a rag below the valve
    • Press the tab on the center of the valve with a pick
  6. step 6 :Removing the EVAP Charcoal Canister
    • Push down on the connector tab and disconnect the fitting
    • Twist off the hose at the top of the canister
    • Disconnect the wiring harness at the top of the canister
    • Move to the rear of the canister
    • Press both tabs together and remove the canister
    • Pry the canister out a bit with a flat blade screwdriver to get it going if needed
  7. step 7 :Disconnecting the Fuel Tank Filler Neck
    • Remove the screw from the hose clamp at the base of the fuel tank filler neck
    • Disconnect the quick connect line
    • Remove the hose from the neck
  8. step 8 :Removing the Gas Tank Strap
    • Loosen the 16mm nut from the tank strap so it sits at the end of the bolt
    • Let the strap hang
    • Repeat the process for the other side, and bring the tank down
  9. step 9 :Disconnecting the Fuel Pump
    • Remove the plastic cover from the forward most part of the gas tank
    • Remove the quick connect line
    • Locate the fuel pump
    • Remove the fuel pump's plastic cover
    • Remove the safety tab on the electrical connector
    • Disconnect the electrical connector
    • Remove the red safety tab on the quick fuel connector line without breaking the red safety. If you do, use a pick to remove the rest of the red safety tab
    • Push down on the tab and remove the line from the pump
    • Drop the strap down
    • Lift the other end up, forward, and down
  10. step 10 :Removing the Gas Tank
    • Have an assistant lift up on the tank on one side
    • Lift up on the tank on the other side
    • Remove the 16mm nuts from the strap
    • Hang the straps down
    • Bring the tank down slowly
  11. step 11 :Reinstalling the Gas Tank and Straps
    • Make sure the filler neck and quick connect line reach over the frame
    • Lay the cover over the top of the fuel pump
    • Lift the fuel tank up into place with the help of an assistant
    • Start the 16mm strap nuts so the tank can hang on the straps
    • Reconnect the quick connect lines and electrical connectors
    • Push the cover over the lock plate
    • Tighten the 16mm gas tank straps
    • Torque the gas tank struts to 30 foot-pounds
  12. step 12 :Reinstalling the EVAP Charcoal Canister
    • Check the canister for cracking through the case
    • Insert the canister into place, front hook first
    • Twist on the hose at the top of the canister
    • Press the fitting into place
    • Connect the wiring harness at the top of the canister
  13. step 13 :Reconnecting the Fuel Filler Neck
    • Reconnect the quick connect line on the fuel filler neck
    • Connect the fuel filler neck fitting
    • Tighten the hose clamp to the filler neck with a flat blade screwdriver
  14. step 14 :Tightening the Schrader Valve Cap
    • Twist the cap onto the Schrader valve
  15. step 15 :Replacing the Airbox
    • Insert the airbox over to throttle body
    • Tighten its 10mm bolts
    • Reconnect the air intake temp sensor
  16. step 16 :Reinstalling the Air Filter Box
    • Insert the lower air filter box into place
    • Insert the air intake box top
    • Connect the PCV breather hose
    • Tighten the air intake hose's clamp
    • Close the air box
  17. step 17 :Connecting the Fuel System Connector
    • Pull down the gray latch on the connector
    • Reinstall the red safety tab
    • Reinstall the fuel cap
  18. step 18 :Reconnecting the Battery
    • Connect the battery's negative terminal
  19. step 19 :Priming the Fuel System
    • Turn the key to the ON position for 3 seconds
    • Turn the vehicle off
    • Repeat the process three times
    • Start the vehicle

Tools needed for replacement

  • General Tools

    Jack Stands

    Pick

    Floor Jack

  • Materials, Fluids, and Supplies

    Rust Penetrant

    Safety Glasses

    Cloth Rags

  • Ratchets & Related

    Socket Extensions

    Torque Wrench

    Ratchet

  • Screwdrivers & Related

    Flat Blade Screwdriver

  • Sockets - Metric

    16mm Socket

    10mm Socket

  • Specialty Tools

    Vacuum

Installation Video
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Hi, I'm Mike from 1A Auto. I hope this how-to video helps you out, and next time you need parts for your vehicle, think of 1AAuto.com. Thanks.

In this video, we're going to show you how to remove and reinstall a 26 gallon fuel tank in this 2008 Dodge Ram 1500. This information may vary slightly on the 34 gallon tanks. The lower the fuel level is, the easier this job is going to be. Having a full tank can make these very heavy, and difficult to remove and maneuver.

Here are the items you'll need for this repair: safety glasses, flat blade screwdriver, 10-16mm sockets, ratchet, socket extensions, rag, pick, penetrating oil, vacuum cleaner, torque wrench, jack and jack stands

Behind the inner wheel well liner on the driver's fender, you'll find a large connector running to the rear harness of the truck. Using a flat blade screwdriver, pry back the red safety as far as you can. Lift up on this grey latch here. You may have to push down. Lift up on the grey latch. Open that up all the way. You don't have to remove this connector. You just have to open the latch to separate the terminals. Open the fuel door, and remove the fuel cap.

Now, when we start our truck, it's going to die. We want to keep cranking for a few seconds after it dies to run the system out of fuel. You'll want to use a 10 millimeter wrench to remove the negative terminal of your battery, and set it off to the side. Open the air box by releasing the metal clips on the side and the rear. Pop it out of its holders, release this hose from the front, and, using a flat blade screwdriver, loosen the clamp on the rear of the inlet pipe. With that loosened up, work the pipe off of the box. Remove this assembly.

The bottom half of your air box simply lifts off its retainers, and comes right out of the truck. Remove the two 10 millimeter bolts: one behind the alternator, and one behind the oil cap, with a 10 millimeter socket, ratchet, and extension.

Lift up on the air box so that you can access the intake air temp sensor at the front. Push down on the connector. Remove it from the IAT. Remove the air box from the vehicle.

On the passenger side of the fuel rail, remove the cap on the schrader or pressure release valve, using a thick rag or paper towel. Place that below the valve to catch any excess fuel that comes out.

Using a small pick, press down on the tab in the center of the valve. We're going to remove our evaporative emissions charcoal canister from our gas tank before dropping our tank, partially to reduce the weight of the tank, and also because now is a good time to inspect this for any cracks or damage, because these often become damaged and can cause check engine lights for the evaporative emissions system leak check.

Push down on this tab in the center of the connector, and work the connector off of the fitting. You may hear a little gust of air when you do this, because there is pressure in this canister. Remove this hose at the top of the canister. Twist it to free it up. Pull that off as well. Push down on the connector. Remove that. Push down on this tab to release the bottom of the charcoal canister from the holder.

This tab's twin is located on the top, so we'll push both of those in. This is where the flat blade may come in handy, as these tabs can be a little sticky sometimes. Release the rear of the canister, lay the canister out, and remove it from its retainer on the front of the tank.

Locate the base of the fuel filler neck. It's going to be under the driver's side of the bed, just before the rear tire. You're going to want to wear safety glasses here, because you're working around fuel. Undo the clamp on the fill tube. You may need to use the screwdriver to pry under the bottom of the hose. Break it free of the metal filler neck. You can also do this with a large hose pick if you have one or you can try to twist it by hand as well as with a pair of pliers if necessary. You just want to be very careful not to tear through the hose in the process.

To release the quick connect bent line, we'll have to push down here. Pull back to remove the fitting. Using a 16 millimeter socket ratchet and extension, we're going to loosen the two long bolts. We're going to loosen the nuts all the way down to the bottom. Allow the straps to hang down before removing our tank. We've soaked ours in penetrating oil, as these do tend to get pretty rusty and want to break. We've loosened it down to the last couple of threads, pushed our strap down to let it hang.

Now, as we loosen the other side, bring the tank down. Remove the plastic cover from the forward most part of the gas tank here. Remove this quick connect line. Locate the fuel pump in the center of the tank, and remove the plastic cover on it. Release the red safety tab on this electrical connector. Push down on the tab, and remove the connector. Be careful not to break off the red safety on the quick fuel connector line. If you do, use a pick to remove the rest of the safety tab, then push down on the tab and release the fuel line from the top of the pump.

With the help of a friend or a floor jack, you're going to lift up on the gas tank, loosen the last few threads of the nut that we left on the straps, bend the straps out of the way, and lower the tank down. Ours is up in the air on the lift, so we've put a work bench underneath here so we don't have to drop it out as far. Be sure to wear safety glasses and any other safety equipment you see fit when removing the fuel tank. Place the nut out of the way once you've removed it.

Hang the straps down. Now, we'll come down slowly to make sure that everything's disconnected. I've got to get around the diff over here. Set her on the table.

When reinstalling the fuel tank into the truck, be sure that these two lines go over the frame right here so they line up with the filler neck when we reinstall.

We're going to lay the cover back over the top of the fuel pump here. We're not going to snap it in yet, because you are going to want to maneuver it around, but you have to run the fuel line and the electrical connector through here onto where they go before we can snap it into place. Make sure that's up there and ready to go.

With the help of a friend, move your tank straps out of the way. Lift up on the fuel tank. Then, be sure that those lines for the filler neck go up over the frame in the correct place. Start the nuts a couple of threads each, and allow the tank to hang down in the straps while we reconnect everything on the top of our pump.

Reinstall the cap at the forward most part of the tank. Reconnect all the fittings and electrical connectors on the top of the fuel tank. Push the cover back over the lock plate. Using the 16 millimeter socket ratchet and extension, tighten up the nuts on the gas tank straps. Torque the tank strap nuts to 30 foot-pounds.

Here we have the EVAP, or the evaporative emissions control charcoal canister. This takes in and holds the evaporative emissions or the fumes that come off of your exhaust as it gets hot and cold in the tank. This canister is full of charcoal, which holds onto those emissions until it's safe for us to send them back through the engine and burn them efficiently. Oftentimes, you can get a check engine light for an EVAP leak.

It's not uncommon for these canisters to develop small cracks in them. While we have ours out of the vehicle, we're going to take a look over it. Just check all the plastic. Make sure that there's no cracking anywhere. We have some little scratches here, but nothing that goes through the case. Check the back, top, sides. Everything looks good with our canister, so we're going to go ahead and reinstall it.

Reinstall the front hook of your charcoal canister. Snap the rear into place. Reinstall the electrical connector. Reconnect the rubber hose on the top, and the quick disconnect on the bottom until it locks into place. Reconnect the quick connect line onto the fuel filler neck until it clicks.

Reconnect the fill tube. Slide your hose clamp over, and tighten it down with a flat blade screwdriver. Screw the cap back onto your schrader valve. Reinstall the end of the air box with the silicone gasket over the end of your throttle body. Tighten up the bolt behind the oil fill cap, and behind the alternator, with a 10 millimeter socket and ratchet and an extension.

Reconnect the intake air temp sensor. Drop the lower air filter housing back onto its mounting locations. Be sure the air filter is fully seated into the housing. Reinstall the intake tube onto the air box, and the PCV breather hose. Lock the lid of the air box back onto its hinge. Close it. Lock it back down, and tighten the intake tube clamp with a flat blade screwdriver. Bring the latch on the connector back down.

Reinstall the red safety tab. Reinstall your fuel cap.

Reinstall your negative battery terminal. Tighten it back with the 10 millimeter socket.

Now, since we released all the pressure and fuel from the fuel system and the fuel rail, we'll have to prime our fuel system. We do this by inserting the key, turning the key to the "on" position for three seconds, turning it off, and repeating that process three times before starting.

Thanks for tuning in. We hope this video helped you out. Next time you need parts for your car, please visit 1AAuto.com. Also check out our other helpful how-to and diagnosis videos.

Tools needed for replacement:

    General Tools

  • Jack Stands
  • Pick
  • Floor Jack

  • Materials, Fluids, and Supplies

  • Rust Penetrant
  • Safety Glasses
  • Cloth Rags

  • Ratchets & Related

  • Socket Extensions
  • Torque Wrench
  • Ratchet

  • Screwdrivers & Related

  • Flat Blade Screwdriver

  • Sockets - Metric

  • 16mm Socket
  • 10mm Socket

  • Specialty Tools

  • Vacuum


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