dozer12216

New gasket with lube and make sure you index into tank correctlly.

JoeCanuck

Hopefully those "next times" are kept to a minimum...for now, even though there's lots left to do on the truck if I want, I'm going to enjoy driving it for a while.

Tate

One more suggestion to lift the bed. When I installed my espar on my dually, I used my 2 ton floor jack to lift the bed up on the one side. Just set it on the frame rail and up it went. Plus you don't have to worry about the bottom of the tank being pushed up and messing up where the fuel tank module height is set. Thats where guys get problems sucking air at 1/4 tank with draw straws, because they take the sag out of the tank.

JoeCanuck

I lifted the bed when I did my aux heater but I had access to an indoor hoist. Lifting one side sounds like a good idea. Hopefully, I'll never need to find out.

dodgerdog

I just went through the ordeal Tate just mentioned - where the mechanic cut the draw straw about 3/4" too short on account of the tank dimension being skewed due to fuel weight and an unmounted fuel tank displacement error. Symtoms observed, thanks to having a fuel pressure gauge were loss of pressure at about 1/4 tank - the very reason we went with installing a draw straw in the first place (FASS pump). I wound up ordering another draw straw from Vulcan, and the mechanic having to rig an out of truck fuel tank supporting fixture to obtain a better tank measurement and in order to obtain a more precise drawstraw length. Now that I have my truck back - time will tell.

Curious to know why removing the truck bed is out of the question - hindsight being 20/20, it would seem like this is the more reliable and easier method regarding issues with the fuel tank?

DD

littlebuddie

I got the tank out fine but was scratching my head for a minute before I realized the cross member had to come off. The most difficult part was undoing those pesky connectors one handed and my face smashed up against the frame. Thank goodness for zip ties! Just detaching those 3 connections deserves its own tech write-up. I didn't move the bed because I am all by myself and also there is a canopy attached. Thanks everyone for your suggestions, they really helped!

olddodgetrucks

took the grinder and cut an access hole in the box and now i can take a few screws out and get at everything

cstroup

littlebuddie Glad you got it goin !!!!!!!!

Olddodgetrucks I did the same thing when I used to be a chevy guy.

Those little fuel pump could go out without notice.

I could swap one out in 20 min.

Every time a got a different 88-94 chevy I would cut a hole in the bed and put a spare fuel pump and strainer in the tool box.

littlebuddie

Thanks cstroup, now all I have to do is fix or replace my fuel module. Thanks everyone for your help.

nerka992003

I'm needing to drop my tank, have some sort of a leak up on the top just draining my tank to lighten the load.

JasonblkZ06

I just did this a few weeks ago. Ran out of fuel due to a false reading from the sending unit. I thought it was a bad lift pump until I pulled the tank and saw there was no fuel in it. I went ahead and put a Vulcan draw straw and Airdog 150 on while I had it dropped. I got so mad at those fuel fittings that I ended up just cutting the lines since I was not going to be reusing them. I should have done that from the beginning instead of wasiting 45 minutes trying to get them undone. I should have thought of the zip tie trick. Let us know if you have any other questions and good luck.

Oh..I just got down to 1/4 tank and no fuel problems yet. Looks like I might have done my draw straw right.

Fern

I dropped mine earlier this week with a half tank, no jacks and by myself. Actually twice cause mine started leaking after I installed my FASS. Its do-able and I'm a skinny guy. Does it leak while sitting or only while driving. I'd try to tighten the collar of the module if it only leaks while driving. just loosten the nuts to the end of thread of the straps to get a little more room to work with.

klx650a2

I have the same issue, bad sending unit and leaking tank. When things slow down, I'm taking my trusty angle grinder and a zip disk and making an access hole. I do not have the time or manpower to drop the tank or remove the bed.

JasonblkZ06

Dropping the tank is not hard. Mine was empty and I used a jack with a block of wood sideways and 2 jackstands on each side in case it fell off the jack. It only weighs 30-40 lbs empty and is easily carried. When I reinstalled it, I put it on my chest and lifted it into place, very easy. I had to take it back down twice though to get access to the lines again.

Make sure the large plastic threaded piece is threaded onto the tank right. It took me awhile to get it, it kept wanting to cross thread. I sprayed some lubricant on it and was patient with it until it took the threads.