1. Preparation:
* Safety First: Disconnect the negative (-) battery terminal. This prevents accidental sparks.
* Empty the Tank: Completely drain the fuel tank. This is crucial to avoid spills and fire hazards. Use a siphon pump or carefully drain it through the fuel line.
* Gather Tools: You'll need various tools, including:
* Wrenches (socket set is best) – sizes will depend on your fuel tank straps and other fasteners.
* Screwdrivers (Phillips and flathead)
* Socket extensions and ratchets
* Jack and jack stands (essential for safety)
* Possibly a fuel line disconnect tool
* Container to catch any remaining fuel
* Safety glasses and gloves
* Consult a Repair Manual: A factory service manual or a reputable CJ-5 repair manual specific to the 1975 model year is highly recommended. This will give you detailed diagrams and specific torque specifications.
2. Access and Disconnect:
* Raise the Jeep: Safely lift the Jeep using a jack and securely support it on jack stands. Never work under a vehicle supported only by a jack.
* Locate Fuel Lines and Vent Line: Identify and carefully disconnect the fuel lines leading to and from the tank. You might need a fuel line disconnect tool to avoid damage. Also disconnect the vent line. Be prepared for some fuel spillage, even after draining; use rags or shop towels.
* Disconnect Electrical Connections: If your fuel sending unit has a wire harness, disconnect it.
* Remove the Fuel Tank Straps: Most likely, the tank is held in place by metal straps secured with bolts. Locate and carefully remove these bolts. You may need to use penetrating oil if they are rusty.
3. Lower the Tank:
* Carefully Lower the Tank: Gently lower the fuel tank. It might be heavy, so have a helper if possible. Be mindful of any potential obstructions (like the exhaust system).
4. Tank Removal:
* Clear the Tank: Once the straps are removed, the tank should be free. You may need to maneuver it slightly to clear any obstructions before you can fully remove it.
Important Considerations:
* Rust: Older CJ-5s are prone to rust. Bolts and straps may be seized. Use penetrating oil liberally and allow sufficient time for it to work before attempting removal.
* Fuel Line Fragility: Fuel lines, especially older ones, can become brittle and break easily. Handle them with care.
* Fuel Spillage: Minimize fuel spillage as much as possible. It's a fire hazard and environmentally damaging.
* Safety: Always prioritize safety. Working under a vehicle that isn't properly supported is extremely dangerous.
Reinstallation: Reinstallation is essentially the reverse of the removal process. Ensure all connections are secure and tightened to the proper torque specifications (as per your repair manual).
This is a general guide. The exact procedure may vary slightly based on your specific Jeep CJ-5 model. Always consult a repair manual for detailed instructions and diagrams specific to your vehicle. If you're uncomfortable performing this task yourself, seek the help of a qualified mechanic.
