After hitting the gas tank on the TJ several times I decided it was time to replace it in order to ensure I had adequate protection. In the process I looked at a few different options and determined that a Gas Tank Skid that raised the fuel tank would be the smartest move. Anything to get extra clearance was probably a good investment. So I was looking at the Kilby Skid because I had found that the items available that actually raised the gas tank up were pretty slim. The only problem I had with the Kilby gas tank skid was the price. It was over $200 and I was hoping to get it slightly cheaper than that. I finally came across a skid plate made by WARN. This skid plate raised the tank up an inch, was 3/16 thick and only cost $156.00 and as luck would have it I could buy this locally and avoid the shipping costs so overall it was a lot cheaper.
As you can see the skid plate is almost identical to Kilby’s skid and it appeared as it may not be a problem to switch these out.
The first part of this switch was to disconnect the electrical and the gas lines. With this in mind the battery was disconnected and then the connector on the gas tank was located. The connector sits on the front side of the gas tank between the gas tank and the track bar. In order to unplug the connector it was necessary to slid the red clip to the side and pull it out to completely release the retaining clip. Once this is done the plugs can be pulled a part with a little effort.
With the electrical disconnected the next part is extremely important. At the nozzle unscrew all six screws. Three around the outer housing/trim and then the three screws holding the neck of the fuel tank to the trim will completely release the fuel neck from the jeep. The other reason for disconnecting these screws is to ensure the pressure inside the tank is allowed to release and the fuel line pressure is reduced.
Pull back the trim piece on the underside of the corner directly underneath the fuel neck. If you look around you should see a grounding strap/wire that is attached to the neck and also attached to the upper shock mount. This is a simple metal clip and can be pushed off with a screw driver, just be careful not to break the clip because you will need it to remount the grounding wire once you put the tank back in.
Next is to disconnect the fuel line and this proved to be the longest part. We had great difficulty actually determining how the high pressure line connect to the gas tank line.
Cut the zip tie that holds the two fuel lines together, this will make it easier to move the lines so they can be removed. If you look closely to at the gas tank lines the evaporation hose is simply pressed on and with a little wiggling can be disconnected. The larger line is the High Pressure Line and has a hose that leads to a black connector with a light grey clip. If you press in on the gray tabs at the top of the line and pull on the black part of the connector. The grey part of the clip will remain with the metal fuel line and will not slide off with the hose and black connector. This was the most difficult part of the installation because the buildup around the clip made it difficult to compress the tabs enough to pull the black clip off. When this tube is slid off the metal line a small amount of fuel will drain from the line, this is a small amount and can be wiped up with a rag.
With the lines disconnected we placed a board under the gas tank with a floor jack and snugged it up against the tank. We then proceeded to undo all the bolts four on the front side of tank, near the axle, and then loosen the four bolts securing the tank on the backside of the gas tank. Once the bolts are disconnected slowly lower the tank with the floor jack until it clears the underside of the vehicle. Slide the tank out from under the vehicle so the straps that hold the tank to the skid plate can be accessed.
Before mounting the new skid with the tank test fit to make sure the skid mounting holes match the bolt pattern on the bottom of the Jeep. If this appears to fit then proceed with removing the tank from the old skid plate and mounting it to the new skid.
With the tank in the open unbolt the straps that hold the tank to the skid plate. Once they are disconnected the whole tank can then be separated from the skid and placed in the new skid.
Reattach the straps being careful not over tighten the bolts, just make sure they are snug. With the gas tank in the new skid plate place it on the board and jack and move the jack under the back of the Jeep.
Raise the tank and help guide mounting holes and fuel neck to their proper positions. As you raise the tank be careful to ensure the fuel and electrical lines do not get trapped on top of the tank, you want to make sure they are accessible in order to reconnect them later.
With all mounts lined up bolt the skid plate to the bottom of Jeep. Reconnect the fuel lines and the electrical line and slid the red clip into the electrical connector to secure it.
Screw the inner fuel neck to the trim and the trim to the Jeep and place the gas cap back on the fuel neck.
