Warn Fuel Tank Skid Plate Installation

Protection for the belly of your Jeep  ◆◆◇◇ Medium


Warn Fuel Tank Skid Installation CompletedOld Skid PlateWhile 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.


I found Quadratec.com selling Warn Fuel Skid Plate for $179.95 plus shipping.  This was the best price I could find anywhere as it was on their monthly special.  Normal price goes for around $240.


The older version of Warn skid plate offered 1" gain in ground clearance.  However, it created some problem with the body lift equipped vehicle that warn revised the design and got rid of 1" gain.



The skid plate did not come with the instruction or any other paper work, not even a warranty sheet.  You can see how the skid plate looks from the following pictures.












From the following pictures, you can see the different between the OEM skid plate and the Warn skid plate.











ComparisonComparisonThese pictures show you where the mounting wiring harness can be attached.  It is very nicely done on the Warn product. 




ComparisonComparisonFrom these two pictures, you can see how Warn has the coverage where the OEM is left wide open.  




ThicknessYou can see the thickness of Warn skid plate here.  The ruller's smallest denomination is in millimeter.





Tools & Parts Needed

Warn Fuel Tank Skid Plate (QuadraTec.com: $200 shipped on Special, weighs 70+ lbs.)

Socket Assortment

Floor Jack

Wood Block


Job Hours

3 hours





Removal Procedure 

ECMECM RelayECM Relay RemovedDisconnect the battery 





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.


RemovalRemoval2. Remove 8 screws that are holding the fuel hose.





RemovalRemoval3. Remove the plastic piece.  You will have access to the ground strap and zip tie holding the axle vent and the fuel hose.  Unhook the ground strap and cut the zip tie.




Removal4. 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.




RemovalRemovalRemoval5. Once the floor jack is placed under the fuel tank, remove 7 nuts holding the gas tank in place. There are 4 nuts in the rear and 3 in the front of the gas tank.



RemovalRemoval6. 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.


Removal7. Everything is now free from the tank to lower the gas tank away from the Jeep.





Removal8. Once freed from the Jeep, it is good idea to move the gas tank away from the Jeep and out of the garage before doing any more work.





RemovalRemoval9. You need to remove two plastic thread protectors before getting to the bolts for the straps.




Removal10. Once the plastic pieces are removed, measure the length of the exposed thread and write it down somewhere.




RemovalRemoval  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.


RemovalRemoval11. Remove the straps and remove the tank.





RemovalRemovalYou can see the debris accumulated underneath the tank.  I can see why they made the tank plastic.





Installation Procedure

RemovalRemoval1. Once the plastic tank is removed, it is a good time for you clean it up a bit.




InstallInstall2. Prepare the wooden block on the floor jack and position the skid plate so it will balance itself on the block.




Install3. Place the metal straps and then place the fuel tank.





Install4. 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.


InstallInstall5. Make sure your lines are routed as shown and secure the electrical connector on the tank.




InstallInstall6. Here is the picture of the finished install of the tank.  On the right you can see the thread protectors installed.




InstallInstall7. Position the assembly under the Jeep towards the passenger side.  Route the fuel hose in place as you raise the tank in position.




InstallInstall8. As the tank is positioned where it should be, make sure the bolt holes line up.






Install9. Connect the fuel line, EVAP, and the electrical connector.





InstallInstall10. Install the ground strap on the body tub as shown and install the trim piece.  You are done working under the Jeep!




Install11. Install the fuel pump relay.  Put the cap back on the PDC. Reconnect the battery.





Install12. You are done!





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.