Here's a general outline. Specific steps and locations may vary slightly depending on the exact trim level and body style. Always consult a repair manual specific to your year and model for detailed diagrams and torque specifications.
1. Preparation:
* Safety First: Disconnect the negative battery cable.
* Gather Tools: You'll need jack stands, a jack, various wrenches (sockets and open-end), screwdrivers (possibly Phillips and flathead), safety glasses, gloves, fuel line disconnect tool, possibly a fuel pump pressure release tool, and potentially a fuel tank strap wrench.
* Locate Access Points: The tank is usually accessed from underneath the truck. You might need to remove some underbody panels or shields to gain better access.
2. Fuel System Depressurization:
* Release Fuel Pressure: This is crucial to prevent fuel spraying. Consult your repair manual for the proper procedure. It might involve removing a fuel pump pressure release valve or simply running the engine until it stalls after turning off the ignition. Never attempt to work near the fuel system with fuel pressure present.
3. Disconnect Fuel Lines and Electrical Connections:
* Fuel Lines: Carefully disconnect the fuel lines going to and from the tank. Use the proper fuel line disconnect tool to avoid damage. Have rags or a container ready to catch any spilled fuel.
* Electrical Connections: Disconnect any electrical connectors related to the fuel sending unit, fuel pump, or other components. Take photos or make notes to ensure proper reconnection.
4. Disconnect the Fuel Tank:
* Support the Tank: Securely support the tank with jack stands or straps to prevent it from dropping.
* Remove Filler Neck: The filler neck might need to be disconnected. This often involves removing bolts or clamps.
* Release Tank Straps: There are usually straps or brackets securing the tank to the frame. Loosen these, often with wrenches, but sometimes a strap wrench is helpful.
* Lower the Tank: Carefully lower the tank, supporting it constantly. Be mindful of the fuel lines and electrical connections that are still attached.
5. Remove the Tank:
* Clear the Area: Ensure you have enough clearance to maneuver the tank out from under the vehicle.
* Tank Removal: Once the straps and connections are loose, carefully remove the tank.
6. Reinstallation:
Reinstallation is the reverse of removal. Be sure to tighten all connections securely and correctly reconnect all electrical connections.
Important Notes:
* Repair Manual: A repair manual specific to your 1996 Dodge Ram 1500 is highly recommended. It will provide detailed diagrams, torque specifications, and crucial safety information.
* Professional Help: If you are not comfortable performing this task, consider taking it to a qualified mechanic. Incorrectly handling fuel lines or the fuel system can be dangerous.
* Environmental Considerations: Properly dispose of any spilled fuel.
This is a general guide. Variations exist depending on specific truck configurations. Always prioritize safety and consult your repair manual for the most accurate and safe procedure.
