1. Preparation:
* Safety First: Disconnect the negative battery cable.
* Gather Tools: You'll need jack stands, jack, socket set (various sizes), wrenches, fuel line disconnect tools, safety glasses, gloves, rags, and potentially a fuel pump removal tool (depending on the approach).
* Locate the Tank: Familiarize yourself with the tank's location and surrounding components.
* Consult a Repair Manual: A Haynes or Chilton manual specific to your year and model Tahoe is highly recommended. It will provide detailed diagrams and torque specifications crucial for success.
2. Fuel System Disconnection:
* Relief Pressure: Carefully relieve fuel system pressure. This usually involves starting the engine and letting it run until it stalls (after several attempts, it won't restart as the fuel is depleted). Consult your repair manual for the proper procedure.
* Disconnect Fuel Lines: Carefully disconnect the fuel lines at the tank. Use fuel line disconnect tools to avoid damaging the lines. Have rags ready to absorb any spilled fuel.
* Disconnect Fuel Sender: Disconnect the electrical connector for the fuel level sender.
* Disconnect EVAP System: Disconnect any vapor emission control lines.
3. Accessing the Tank:
* Raise the Vehicle: Securely lift the Tahoe using jack stands. Never work under a vehicle supported only by a jack.
* Remove Access Panels: You'll likely need to remove panels under the vehicle to gain access to the tank straps and other components.
* Remove Tank Straps: There are usually straps securing the gas tank to the vehicle's frame. Carefully remove these straps. This often involves bolts and potentially nuts.
4. Lowering the Tank:
* Lower the Tank Carefully: Once the straps are removed, you can carefully lower the tank. It might be heavy and awkward, so have a helper if possible.
* Support the Tank: Use a suitable support to prevent the tank from dropping suddenly.
5. Post-Tank Removal:
* Inspect Tank and Lines: Carefully inspect the tank, fuel lines, and other components for damage.
* Complete the Repair/Replacement: Perform your intended repairs or replacement.
6. Reinstallation:
* Reinstallation is the reverse of removal: Carefully reattach all components, ensuring everything is properly seated and tightened to the correct specifications (consult your repair manual).
* Reconnect Fuel Lines: Carefully reconnect fuel lines and the electrical components.
* Lower the Vehicle: Lower the vehicle slowly and carefully.
* Reconnect Battery: Reconnect the negative battery cable.
Important Considerations:
* Fuel is Flammable: Take extreme caution when working near fuel lines and the tank. Avoid sparks and open flames.
* Exhaust System: Be mindful of the exhaust system; it can get very hot.
* Weight: The gas tank is heavy. Get help if needed.
This is a simplified overview. Always refer to a repair manual specific to your 1996 Chevy Tahoe for detailed, step-by-step instructions and safety precautions. If you're not comfortable performing this task yourself, take it to a qualified mechanic. Improper handling of the fuel system can be dangerous.
