Attention: TDR Forum Junkies Thanks to Spooled-up I took the plunge and dropped the fuel tank to make the modification.
The fitting I used for the top of the tank was made from a brass fitting with npt threads. The fitting was 1/4 npt female on one end and 1/8 npt male on the other. I took a 3/8 NF die from the tap & die set, redid the threads on 1/8 npt side to 3/8 NF. That would give me a straight shank to work with. I went to my local auto parts store and bought 1/4 npt street el with a 3/8 barb for the vent hose. While I was there I got 2 oil drain plug gaskets to fit the 3/8 shank. Also while I was there I went to where they had the HELP display. There I found a heater hose tee fitting with 3/4-3/4-3/8. The original vent hose on the truck is 3/4 fuel hose.
First I had to empty the tank. (23 gal. ) I completely removed the filler from the steel tubing to the tank and put it aside. Then I removed all the fuel from the tank. I removed the fuel fittings ( pinch the 2 plastic tabs on the quick connects and the fuel hoses will come off and slide the orange tab on electrical and release the tab at back and electrical connector is easily removed). After all the fuel was removed I cut the original vent tube leaving about 3 inches attached to the steel tube. I sprayed the 2 bolts holding the tank with some silicone spray and then turned the 2 15mm bolts down with a 15mm box end wrench to where I was able to use a 5/8 deep socket, (didn't have 15mm deep socket) 8 in. 3/8 extension and 3/8 butteryfly air tool to almost remove the bolts. I used a floor jack with a 2' 2x6 to lay on the lift part of the jack to give a little more stability and then completely removed the 15mm bolts holding the tank. I used the floor jack to let the tank down to where I could remove it from under the truck. I had nothing to move the plastic ring from the sending unit. So I used a small oak block of wood and gently tapped on the edge and it came loose fairly easy. I removed the sending and there was maybe a gallon of fuel still in the tank. I located the place where I wanted to drill the 3/8 hole and put a big rag in the tank to catch the shavings. Then I used laquer thinner to clean the area and installed the fitting with gasket above and below the fuel tank. I did like Spooled-up and used loctite (red) on the threads. On the threaded pipe fittings I used teflon tape. I also used a little JB Weld around the fitting on top of the tank. I reinstalled the sending in the tank put the plastic ring back on and it was marked to where how tight I needed to turn the ring. I put the tank back under the truck and blocked it up with 4x4 and 2x6's to get it high enough to get the floor jack and 2x6 under it and raised it to where I could support it with the straps and nuts. I then installed the 3/8 fuel hose for the vent and ran it along on the outside of the frame and then reconnected the fuel hoses and electrial connection. I run the 2 15mm bolts up as far as I could with the air tool and then finished off the box end wrench. Next I replaced the filler hose on the tank and to the steel filler tube. I installed the heater hose connection in the original vent tube leaving the 3/8 barb exposed to receive the new vent hose. I checked all clamps to be sure I hadn't missed any. Today I had a dental appt. and on the way home I filled the tank (a little over 18 gal. plus the 23 gal. +- I removed gives a total of about 40 gals. +- which is what I read some other members had put in their trucks).
I want to thank Spoole-up again for this engineering job. It make the truck much easier to fill. There was still the foam but that was nothing. Now I won't be embarrased to fill my truck.
Hope this helps some of the members.
2004 2500 reg cab lwb slt 2wd ho 48re 3:73
J ASHCRAFT
The fitting I used for the top of the tank was made from a brass fitting with npt threads. The fitting was 1/4 npt female on one end and 1/8 npt male on the other. I took a 3/8 NF die from the tap & die set, redid the threads on 1/8 npt side to 3/8 NF. That would give me a straight shank to work with. I went to my local auto parts store and bought 1/4 npt street el with a 3/8 barb for the vent hose. While I was there I got 2 oil drain plug gaskets to fit the 3/8 shank. Also while I was there I went to where they had the HELP display. There I found a heater hose tee fitting with 3/4-3/4-3/8. The original vent hose on the truck is 3/4 fuel hose.
First I had to empty the tank. (23 gal. ) I completely removed the filler from the steel tubing to the tank and put it aside. Then I removed all the fuel from the tank. I removed the fuel fittings ( pinch the 2 plastic tabs on the quick connects and the fuel hoses will come off and slide the orange tab on electrical and release the tab at back and electrical connector is easily removed). After all the fuel was removed I cut the original vent tube leaving about 3 inches attached to the steel tube. I sprayed the 2 bolts holding the tank with some silicone spray and then turned the 2 15mm bolts down with a 15mm box end wrench to where I was able to use a 5/8 deep socket, (didn't have 15mm deep socket) 8 in. 3/8 extension and 3/8 butteryfly air tool to almost remove the bolts. I used a floor jack with a 2' 2x6 to lay on the lift part of the jack to give a little more stability and then completely removed the 15mm bolts holding the tank. I used the floor jack to let the tank down to where I could remove it from under the truck. I had nothing to move the plastic ring from the sending unit. So I used a small oak block of wood and gently tapped on the edge and it came loose fairly easy. I removed the sending and there was maybe a gallon of fuel still in the tank. I located the place where I wanted to drill the 3/8 hole and put a big rag in the tank to catch the shavings. Then I used laquer thinner to clean the area and installed the fitting with gasket above and below the fuel tank. I did like Spooled-up and used loctite (red) on the threads. On the threaded pipe fittings I used teflon tape. I also used a little JB Weld around the fitting on top of the tank. I reinstalled the sending in the tank put the plastic ring back on and it was marked to where how tight I needed to turn the ring. I put the tank back under the truck and blocked it up with 4x4 and 2x6's to get it high enough to get the floor jack and 2x6 under it and raised it to where I could support it with the straps and nuts. I then installed the 3/8 fuel hose for the vent and ran it along on the outside of the frame and then reconnected the fuel hoses and electrial connection. I run the 2 15mm bolts up as far as I could with the air tool and then finished off the box end wrench. Next I replaced the filler hose on the tank and to the steel filler tube. I installed the heater hose connection in the original vent tube leaving the 3/8 barb exposed to receive the new vent hose. I checked all clamps to be sure I hadn't missed any. Today I had a dental appt. and on the way home I filled the tank (a little over 18 gal. plus the 23 gal. +- I removed gives a total of about 40 gals. +- which is what I read some other members had put in their trucks).
I want to thank Spoole-up again for this engineering job. It make the truck much easier to fill. There was still the foam but that was nothing. Now I won't be embarrased to fill my truck.
Hope this helps some of the members.
2004 2500 reg cab lwb slt 2wd ho 48re 3:73
J ASHCRAFT
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