DETAILED Gas Tank Removal and Fuel Line Connectors - Project 2004 Jeep Wrangler TJ

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I decided to make a high quality (4K Video) and very detailed look at the gas tank removal on my son's 2004 Jeep Wrangler TJ. I believe there will be subtle differences year to year, but this should be helpful for any TJ owner looking to drop their tank... either to replace a rear bumper, replace the fuel tank skid plate, change out a fuel pump, or make room to work in the rear of the Jeep.
The actual tank removal isn't that difficult. The space it gives to work back there is well worth the time to remove it, in my opinion.
I also cover in close-up detail how to disconnect the fuel line connectors (which was another thing I was searching for info for). These are simple push connectors, and were very easy once I understood how they worked.
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[@anthonyguilianoii8836]

Love the music! I'm going to go drop my fuel tank right now and jam out as well! 🤘

[@christopherdaley6304]

Please keep the project TJ videos coming. This saved me a ton of headaches when I changed my fuel pump (and while it was out I cut the frozen upper rear shock mount bolts)

[@VsixtyFive]

Thanks for the electrical tab instructions!! I spend more time figuring them out than the actual repair!!!

[@BartonGeoff]

Thank you! This is perfect. I was dreading removing all those hose connections. Having a detailed video to watch makes it all so much easier.

[@thomasbusick5507]

THANK YOU! Even though I had a full tank it wasnt hard using this video. I had to replace the hose lines so the explanations of those helped too

[@nevadaboy9769]

BTW for future reference for anyone needing to know the fuel line connector clip size of the 3 on the drivers side 2 are 5/16 white clip & one is 3/8 black clip Dorman # 800-023 you will get 3ea in the pkg the big evap line connected to the tank on the passenger side is 5/8 Dorman # 800-041 by chance if you need the 1/2" its Dorman # 800-040 probably wouldnt hurt to get all of them & if your in a bind just thead the same size ziptie thru the connector works just fine you cant pull it off ✌

[@MRACGun]

Woah! Every video I have seen with people removing those tabs says to pry them out with a small screwdriver.. That is so much easier. You the man

[@marydreeszen960]

Dude, I've soaked them with PB blaster and they just will not come off. I press the detent and see the little claw open as if it were releasing the fuel line but it won't come off. 03 Rubi.

[@SpudKai]

Thanks for the Video. My 2000tj was relatively easy. Tank was about half full. No issues. My connectors were all on the drivers side. 3 hoses and one electronic connector. Now I'm going to clean my skid plate up and paint it with corroseal then rust bullet!

[@MikeUtah]

You sir, are an outstanding teacher. Thank you.

[@hhyperdd]

That was awesome.Thank you.

[@gamrkidd]

thanks! immediately convinced me that this is no job that I have the capability of doing on my 2003 wrangler X - stupid p0455 and p0422 codes - seems like its the evap can that's the problem smh

[@IFHSP2]

Very helpful. Getting ready to swap out my tank.

[@chriscraft77022]

you earned a sub... best video on the subject.. i just bought a jeep and i wasnt sure how mopar connected the lines..

[@meinbherpieg4723]

Great video. Thank you

[@velixzeen]

Excellent video, all the details and good views of tight situations with the lines, etc. Thanks a ton!

[@AdventureDarin]

Great coverage! Thanks you so much!

[@stevesarkees1953]

Awesome! Thanks for this. Removing mine today as part of my LS swap. Really helps knowing whats hidden.... I cat understand why 9 people dislike your video. Trolls I guess.

[@seanwright4192]

TIP: If your nut-serts start spinning, use a pry bar between the skid plate and the frame. Apply a downward pressure and try unbolting. I had three nuts that spun, got them all off this way. Now the question is do I weld in new ones?

[@DwadeIsHere2010]

Yep the lines up by the filler neck has to do with the Evaporative emissions system. Witch I find that system ok when it works and a big hassle for people to make it sealed again. So I assume one line is the raw fuel but the others are the Vapor out to the engine to be burn and fresh air to be drawn into the intake on the evap canister. I recently learned through KZbin about the Evaporative system and what's its purpose is.

[@Blaydrnnnr]

My sons '98 TJ Jeep is a rusted, corroded mess. Its need the shocks done, ( after seeing your vid on broken bolts.. not a chance in hell on the back ones, MAYBE the fronts....) and the rotors and a radiator. I use Kroil instead of PB Blaster. Its MUCH, much better. But even though, theres no saving the bolts on his rear shocks. And getting the tank out from under that thing is not gonna happen, so to fix the bolts is a no go at this point. He's gonna have to ride those things until that Jeep is dead.....LOL Great vids, I learned alot....

[@extremeduty2570]

Are '06 connections the same? Good video.

[@ONE_GEN_X]

Those connectors look easy. Too bad my 2006 has something different that is kicking my butt

[@Blaydrnnnr]

Maybe a good time to change out the fuel pump as well?

[@TheNotSoOrdinaryCarGuy]

My front 3 bolts that hold the fuel tank skid plate are rusted to the point that the sockets wont bite them at all, any size. I'm tempted to just dremel them off like I plan to do to the nuts on the rear upper shock mounts. Other than that I'm not sure what to do.

[@johnford3761]

If all I’m doing is installing a rear bumper do I need to disconnect everything to drop it enough to drill the bolting?

[@2_fitnesss523]

That’s a great video. I have a 2000 Jeep Wrangler that is leakier fuel from the sending fuel line that is attached to the top of the fuel tank. I changed the whole fuel line and it is still leaking from the same place. Did i buy the wrong one? Or is it possibly a damaged fuel pump. Thanks

[@pujo28]

The line u removed @3:25 mark. Mine has no connection that runs to the tank. It looks like it was removed possibly when my frame n skid plate were repaired recently. Do u know where that evap line goes to on the tank. Mine runs up the frame to the bottom of the charcoal canister in my 2001 tj. Wondering if I have to drop tank to see if the line is laying there waiting to be reconnected?

[@nordland2235]

Do you know what part I need to buy......my metal fuel lin thgoes down the frame on the drivers side to the back......the soft line that connects to the metal fuel line is broke...and my 97 tj is getting no fuel.....can you tell me what part to buy...desparate to get my jeep going.

[@fredjunk]

Thanks for the info. The background music is annoying as hell when trying to listen to your instructions.

[@joshnasche5495]

Is that the 15 gallon or 20 gallon fuel tank? And going to put a bigger gas tank in or keep what you have?

[@generaldrz]

I'm about to try on my 2000, I only see fuel line, vent line and electric connect

[@jamesray388]

I came across a rattle around my gas tank and found this video. Can someone tell me, @ minute 8:31 there is a blue piece of metal holding up something plastic. Does anyone know what this is?

[@philoeolivarria448]

Great video......how many gal. Tank is in the tj.....I have a 1999

[@krisdesha8129]

19 gallon tank, but I believe the 2.5l came with 15 gallon, which was actually just a longer vent tube that extended into the tank. There is a mod to remove it. I am going to try it out on Sunday.

[@Blaydrnnnr]

Anyone know if the fuel line connectors are the same on an older version? 1998?

[@mattseiler2030]

I just removed my tank as well, and also have some fuel left in it. What is the best way to store the tank when it still has fuel in it?

[@o3djeeps]

I'd put some fuel stabilizer in it... like sta-bil

[@wpierre1994]

Next to a fire

[@Suesonly]

Fuel pump is going on my '04 Wrangler so I went to remove the tank and 3 of the bolts are just spinning. Does anyone know what size Carriage bolts I will need to buy to replace bolts? Also previous owner broke compression fittings and just clamped hose on either end for the fuel line :( - please don't be one of those people. I have found so very many band-aid fixes that have cost me HOURS of headaches and extra work!

[@o3djeeps]

Here is what I replaced my hardware wtih: 5/16-18 x 1" carriage bolts (Product #18273) 5/16-18 flange nuts (Product #17671) I bought them from boltdepot.com

[@Suesonly]

@@o3djeeps Awesome - Thank you! I don't know how everyone else's vehicles look so good - I have to wipe grime and dirt off all my connectors just to see them :(

[@isaiasrodriguez4638]

why did you remove the fuel tank?

[@JeepingNet]

He says at :30

[@marydreeszen960]

If you are installing most after market bumpers you will have to install mounting bolts that can only be accessed installed/removed if you drop the fuel tank.

[@specialized29er86]

Snapped shock bolts : ( nothing ever goes as planned.

[@o3djeeps]

Specialized 29er story of my life LOL

[@Greivous429]

Pb blaster is pretty useless in my experience. We call it cat piss because it stinks like it.

[@geneneill530]

I can't stand that "music" in the background. Well, actually that's not accurate. It's not in the background, it's in the FOREGROUND. This might be a great video, but I'll never know. I gave up and went insane after one minute.

[@1ScottPhoto]

GET RID OF THE F**KING BACKGROUND MUSIC!

[@FTell92]

Please turn down the music in next video :) Where does the tubs gose on the right side? Is that some sort of air filter? Is it nesesery?

[@o3djeeps]

I think it's emissions stuff

[@renof2505]

Wow, a lot of extra crap on an 04 vs. an 01. What is with the background music? Very annoying.