How to Remove a Toyota Truck Gas Tank

Gas tanks need removal for various reasons. They can become contaminated with water or some other substance, in which case they have to be removed and completely flushed out so that no damage is done to the engine. Old gas tanks can develop rust and sediments that can clog the fuel filter and will need removal and replacement.

Difficulty: Moderately Challenging

Instructions

Things You'll Need:

• Hydraulic jack
• Large blade flat tip screwdriver
• 1/2-inch drive impact socket set
• 1/2-inch drive air impact wrench
• Shop air up to 120psi
• OSHA-approved hazardous waste disposal container
• 5/8-inch line wrench
• Crescent wrench

How to Remove a Toyota Truck Gas Tank

1. Move the hydraulic jack under the center of the gas tank and close the hand valve.

2. Lift the jack up to even with the gas tank so that when the straps are removed, the hydraulic jack will support the tank's weight. (If the gas tank has a drain valve, drain the gas before completing this procedure).

3. Loosen the screw clamp holding the fuel-line connecting hose in place with the large-bladed flat-tip screw driver. Turn the screw counterclockwise to loosen.

4. Place a drip pan under the fuel-line hose to catch any residual fuel in the line. (Wear safety classes at all times during these procedures. Gasoline is a serious eye hazard).

5. Loosen and disconnect the fuel inlet line from the gas tank by turning the wrench clockwise and holding the fitting still with the crescent wrench.

6. Select the appropriate size impact socket that matches the bolts holding on the gas-tank retaining straps.

7. Attach socket to impact wrench and wrench to shop air.

8. Loosen each retaining strap bolt by squeezing the impact wrench trigger set to counterclockwise rotation. Loosen bolts evenly so that the weight of the gas tank settles evenly onto the hydraulic jack.

9. Remove all four retaining strap bolts and remove them from your work area.

10. Lower the hydraulic jack by turning the hand valve slowly so that the gas tank comes down on the jack evenly.

11. Pull the hydraulic jack with the gas tank on top, slowly out from under the truck.

12. Set the gas tank top side down on the opening of the hazardous waste container. Allow all gasoline to drain out before making repairs.

Tips & Warnings

• Some models have the spare tire located over the gas tank. Follow the service manual procedure for removing the tire. Then follow these steps to remove the gas tank.
• Be careful to lower the tank evenly so that the gasoline does not run to one side or the other and cause the tank to fall off the jack.
• Wear safety glasses at all times during this procedure. Gasoline is a significant eye hazard.
• If gasoline gets in your eyes, flush with clean water for five minutes and call 911 for assistance.
• Consider wearing a face shield when disconnecting the fuel line from the fuel tank to prevent residual gasoline from dripping in your eyes.
• Gasoline vapor is highly flammable. Do not do this procedure near any ignition source.

Who Can Help Sponsored