Extended Cab Side Tank

Fuel Tank:

Fuel Hoses:

Removal Procedure
Disconnect the negative battery cable under the following circumstances:

- When installing an electrical unit.
- When a tool or equipment could easily come into contact with "live" exposed electrical terminals.

Failure to disconnect the negative battery terminal may result in personal injury or damage to the vehicle's components. Turn OFF the vehicle ignition, unless instructed otherwise.

1. Disconnect negative battery cables.
2. Drain the fuel from the tank. Refer to Draining Fuel Tank. Fuel Tank Draining
3. Raise the vehicle.
4. Loosen the filler neck hose clamp at the fuel tank and disconnect the fuel tank filler neck from the fuel tank.
5. Support the fuel tank and remove the tank straps and insulator strips, if equipped.
6. Lower the fuel tank shield.
7. Lower the fuel tank.
8. Disconnect the fuel hoses and lines. Disconnect the electrical connections at the sender.
9. Remove the fuel sender assembly and seal ring, using tool J 39765. Discard the old seal ring. Purge the tank, if the tank is being repaired.

Installation Procedure
1. Install the new seal ring.
2. Use tool J 39765 in order to install the sender.
3. Raise the tank slightly and reconnect the fuel hoses, the lines, and the electrical connections at the sender.
4. Raise the tank fully.
5. Install the fuel tank shield.
6. Reinstall the fuel tank filler neck to the tank.
7. Tighten the clamp.
8. Install the fuel tank brackets with insulator strips in place.

NOTE: The strap nuts must be tightened by steps, alternating between the four nuts until the specified torque is reached. Otherwise, the bottom of the tank will flex upward and the fuel gage will indicate fuel remaining in the tank when the tank runs dry.

9. Tighten the strap nuts to 45 Nm (33 lb. ft).
10. Replenish the fuel in the tank.
11. Reinstall the fuel tank filler cap.
12. Reconnect the negative battery cable. If a memory retention device was not used, please reset (to the extent possible) all devices that lost their memory after the battery was disconnected.
13. Check for leaks.