Here's a general outline of the process. This is not a complete, step-by-step guide and may not cover all variations specific to your Bronco II. Always consult a repair manual specific to your vehicle year and model for detailed instructions and diagrams.
1. Safety First:
* Disconnect the battery negative terminal. This is crucial to prevent sparks.
* Ventilate the work area. Fuel vapors are highly flammable. Work outdoors or in a well-ventilated garage.
* Wear appropriate safety gear: Gloves, eye protection, and possibly a respirator.
* Obtain a fuel-safe container to collect the remaining fuel in the tank. This is not a job to do without properly draining the fuel first!
2. Fuel System Depressurization:
* Carefully relieve fuel pressure. This usually involves disconnecting the fuel pump relay or fuse and running the engine until it stalls (consult your repair manual for the specific procedure). This is essential to prevent fuel spraying. Be extremely careful; fuel under pressure can cause serious injury.
3. Fuel Tank Removal:
* Drain the fuel tank completely. Use a siphon pump or drain valve if equipped.
* Disconnect the fuel lines. Mark the lines clearly to ensure proper reassembly. Use fuel line clamps to prevent leaks.
* Disconnect the fuel sending unit. This often involves electrical connectors and possibly fuel lines connected to the sender.
* Disconnect the vent line.
* Remove the fuel tank straps. These are usually bolts or clamps securing the tank to the frame. You'll likely need various tools, including sockets, wrenches, and potentially a ratchet.
* Lower the fuel tank. This may require careful maneuvering to avoid damaging surrounding components. You might need assistance to support the weight.
4. Fuel Tank Replacement:
* Inspect the new fuel tank and associated components. Ensure everything is in good condition.
* Install the new fuel tank. This involves reversing the removal process: secure the straps, reconnect the vent line, fuel sending unit, and fuel lines. Double-check all connections for leaks.
* Reconnect the fuel lines. Tighten all clamps securely.
* Reconnect the fuel sending unit and electrical connectors.
* Reconnect the fuel pump relay or fuse.
5. System Test:
* Reconnect the battery negative terminal.
* Check for leaks. Carefully inspect all connections for any fuel leakage.
* Start the engine and check for any fuel-related issues. Listen for unusual noises from the fuel pump. Check the fuel gauge.
Important Considerations:
* Rust and Corrosion: The fuel tank may be rusted or corroded, making removal difficult. Use penetrating oil to loosen bolts.
* Accessibility: The fuel tank's location may make access challenging, requiring removal of other components.
* Repair Manual: A factory service manual is essential. It will provide specific torque specifications, diagrams, and instructions for your particular Bronco II.
* Professional Help: If you lack experience or are uncomfortable with this task, consider hiring a qualified mechanic. The risks involved with fuel handling make this a project best left to experienced individuals.
This is a simplified overview. The actual procedure will be more complex and require more detailed steps. Always consult a repair manual and prioritize safety. Improper fuel handling can result in serious injury or even death.
