Models: ALL, Years: ALL

Removal and disassembly of 75 ltr fuel tank (from a 710K)

1. Drain remaining fuel from tank by using a 10mm Allen wrench to remove plug from bottom of tank.     Once fuel is drained reinstall plug.

2. I suggest removing the right front tire for easer access to the work area.

3. Remove the rock guard from the front of the fuel tank by loosening the (2) 13mm bolts (Do Not Remove them) and remove the (2) 10mm bolts on the side and the (2) 10mm bolts at the bottom.    

4. Remove inner shield by loosening the (2) remaining 10mm bolts near the body mount.

5. Disconnect the hose that runs from the pickup tube and the fuel pump. [Caution there will still be fuel in the hose]

6. Remove the access plate that covers the Fuel sender.  This is located under the table on the right side just below the Accessory Power Panel. Remove the (4) Phillips head screws and then the plate.  Now carefully slide off the electrical ?Spade Type? connector from the sending unit.

7. Remove the front passenger seat.  A bellows type cover should now be seen between the body fuel inlet and the cab floor.
Remove the hose clamp located at the top of the bellows.

8. Slide bellows down until (2) hose clamps on the inner filler hose are exposed.

9. Remove the lower hose clamp.

10. Support the fuel tank with a floor jack. I used a mike crate as a spacer because the stroke of my jack was not long enough and I needed something that would avoid the drain plug.

11. With the jack snug against the tank, remove the (2) 13mm bolts from the front that you loosened earlier. Then remove the (2) 13mm bolts from the rear of the tank.  These are located in the foot well when you open the right rear door.

12. Rock the tank slightly and make sure that the only items holding the tank are the filler neck and the vent tube on the top.

13. Let the jack down about 1 inch and carefully pull the filler neck through the bellows type boot a short distance.

14. Inside the cab, see if you can now separate the lower part of the filler hose from the tank inlet pipe. 

15. Repeat step 13.

16. You should now have enough space to disconnect the vent hose from the vent tube and remove the hose from the hose retainer on the top of the tank.

17. Repeat step 13 until the tank is free from the truck body.

18. Inspect body for any repairs needed while tank is out.

19. To remove the sending unit. <Image 13> Loosen the (5) Phillips head screws. (Do Not remove them) <Image 15> There is a gasket between the tank and the bottom of the sender head that must be kept intact. Carefully pry the sender up from the tank by lifting on the flange of the sender.  Once the gasket begins to separate from the tank use a putty knife to aid the separation. Once the gasket is completely separated from the tank, loosen the bolts until the sender can be removed straight up from the tank. (Again Do Not remove the bolts from the sender) It could be very easy to lose the small parts and one bolt location is the ground for sender.

20. To remove the Pick-up tube remove clamp that holds out let tube.  Next repeat the same process in step 19 except the Pick-up assembly slides diagonally up and out of the tank, once the gasket seal is broken.

21. To drain any remaining fuel from the tank, remove a 10mm bolt located in the upper rear corner on the removed tank and rotate tank until that hole becomes the lowest point.

22. To reinstall, assemble in reverse order.

Contributed by Ken Anderson