Warn Fuel Tank Skid Plate Installation
Protection for the belly of your Jeep ◆◆◇◇ Medium
While I was trying to tag along a 4 wheeling club ride, I found that my TJ is not equipped enough to ride safely with them. Since my jeep only has been a scenic drive vehicle, ;) I haven't paid much attention underneath the jeep; it was seriously lacking some protection for vital components under the Jeep.
One of the components, that needs protection for safe trail ride is the fuel tank. Even though factory has equipped the plastic fuel tank with thin sheet metal for skid plate, this is not sufficient enough to keep the fuel tank safe on a moderate trail.
Tools & Parts Needed
Warn Fuel Tank Skid Plate (QuadraTec.com: $200 shipped on Special, weighs 70+ lbs.)
1. First, the fuel line must be depressurized before removing the fuel tank. You do this by removing the fuel pump relay located inside of PDC and cranking the Jeep. The engine will start briefly and die or simply won't start at all. This means there is no fuel being fed into the engine and this is exactly what we are trying to do. Remove the negative battery cable.
4. Place the floor jack with wooden block under the fuel tank assembly right under the dimple. This will allow you to balance the gas tank when you are lowering the tank out of the Jeep. ** Try to run the Jeep as empty as you can before you do this step.
6. Disconnect the fuel line, EVAP, and the electrical connector. The electrical connector has locking tap you need to disengage. The fuel line also has locking mechanism, press the gray tab, remove it away from the black line. Gray tab will stay with the metal line.
The factory service manual specifies that when you replace the plastic tank, it has to be installed so that the length of exposed thread is 30mm +/- 2mm. However, mine was already at 27mm, even though I was puzzled, I decided to keep the reading and use this later.
4. Strap down the tank using the metal strap. I tightened the strap so that it will expose 24mm of thread on both sides. The reasoning is, the increase in thickness of the skid plate has to be compensated. So I tightened less than original. If you tighten this down too much, you will be crushing the tank. You can damage the tank, and the fuel pump assembly. I heard stories where the fuel tank gauge started reading inaccurately after the fuel tank install. I figure it happens because people improperly tighten down the tank.
If you have any questions or recommendations, please let me know!!
I tried my best to document as much as possible along with pictures. I hope you find them useful. However, do use the information provided here "as-is". DailyDrivenTJ.com or the author does not warrant or assume any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, or process disclosed. Use the information at your own risk.
Written by Michael on 8.14.2006.