Removing the gas tank from a 1973-1987 Chevy truck can be a straightforward process if you follow the right steps. This guide is designed for truck owners who are looking to replace or repair their gas tanks due to leaks or other issues.

Preparing for Gas Tank Removal

Before starting, ensure you have the necessary tools and safety equipment. The target audience for this guide includes DIY enthusiasts and truck owners who may not have extensive mechanical experience but want to tackle this task themselves.

Important Tools Needed:
  • Floor jack or jack stands
  • Basic hand tools (wrenches, sockets)
  • Safety goggles and gloves
  • Fuel siphon (if tank is not empty)
  • Replacement hoses and parts (if needed)

Safety Precautions:
  • Always work in a well-ventilated area.
  • Wear safety goggles and gloves.
  • Ensure the fuel tank is as empty as possible to prevent spills.

Steps for Gas Tank Removal

Step 1: Siphon Fuel

If the gas tank is not empty, use a fuel siphon to remove as much fuel as possible. This step is crucial as a full tank can make removal difficult and hazardous.

Step 2: Support the Tank

Using a floor jack, place it under the gas tank. This will help support the weight of the tank when you start to lower it.

Step 3: Disconnect Fuel Lines and Wires

  • Remove the filler neck: Disconnect the fuel filler hose and any vent lines attached to the tank.

  • Disconnect electrical connections: Unplug any wires connected to the sending unit. There may also be a ground wire that needs to be removed.

Step 4: Unbolt the Tank

Locate and remove the bolts securing the tank brackets to the frame. There are typically four bolts per bracket.

Step 5: Lower the Tank

Slowly lower the tank using the floor jack. As you lower it, ensure that all hoses and wires are clear of any obstructions.

Step 6: Remove the Sending Unit (if necessary)

If you're replacing the sending unit, carefully remove it from the tank. Be cautious as this part can be fragile.

Step 7: Remove the Tank from Under the Truck

Once everything is disconnected, slide the tank out from under the truck. If you encounter resistance, double-check that all connections have been removed.

Tips for Reinstallation

When reinstalling your new or repaired gas tank, follow these guidelines:

  • Ensure all seals and grommets are in good condition before installation.

  • Reconnect all hoses and electrical connections securely.

  • Double-check that all bolts are tightened properly to avoid leaks.

StepAction
1Siphon fuel from tank
2Support tank with floor jack
3Disconnect filler neck and wires
4Unbolt tank brackets
5Lower tank carefully
6Remove sending unit if needed
7Slide out tank from under truck

FAQs About Gas Tank Removal

    • Do I need to remove the bed of my truck?
      No, it is not necessary to remove the bed. However, some prefer this method for easier access.

    • What if my sending unit is damaged?
      If your sending unit is damaged, it's best to replace it while you have access to the tank.

    • How do I ensure there are no leaks after installation?
      After reinstalling, check all connections and run a test with fuel before fully securing everything.

Following these steps will help you successfully remove and replace your gas tank on a 73-87 Chevy truck. With patience and careful handling, this task can be accomplished with basic tools and minimal mechanical experience.