Gas Tank Fix
Speaking of gasoline, this Wrangler has had the gas burp problem when filling the tank ever since I bought it. It was irritating, but liveable, and I planned on doing the fix eventually. Then one day it suddenly switched to the extremely slow fill problem. Now that was intolerable, standing at the pump trickling gas into it, with a long line of cars waiting behind me.
So I drove it around until the gas light came on. Then I read various forum posts, and watched half a dozen YouTube videos on how to do the fix. Most of the videos are for older TJs, but mine is a 2005. The '05 and '06 have a different fuel pump and different gas line connectors. Between all of the videos I found enough info to remove the tank without breaking any connectors, and remove the fuel pump. It took about 1.5 hours to drop the tank.
I cleaned up the top of the tank, scraping it and using compressed air. Then I drove off the lock ring with a large ground-off screwdriver. That took another 45 minutes. After removing the fuel pump, I popped out the check valve. Sure enough, the float was sticking in the housing.
I filed the three sets of little dual tracks down about half way. Trying it in the housing, it was pretty free, but I filed a little more until it had some freeplay all the way up and down in the housing. I didn't want it to swell a little more and stick again.
After replacing the check valve in the tank, I installed a new Bosch 67756 fuel pump with sender (from Rock Auto, best price I could find). This is the identical fuel pump to the Mopar OEM one. My old pump was working fine, but at 100K miles I didn't want to have to drop the tank again soon if it died.
I installed the tank in the Jeep in another hour+. I turned on the key and let the pump run for a few seconds, until it sounded like it had pressured up the line, and then checked for leaks. Then it took another 10 or 20 seconds to crank it to life. No leaks, everything works right.
And I filled the tank with no slowdown, and no burp. Another Mopar screwup fixed. Wonderful.
Speaking of gasoline, this Wrangler has had the gas burp problem when filling the tank ever since I bought it. It was irritating, but liveable, and I planned on doing the fix eventually. Then one day it suddenly switched to the extremely slow fill problem. Now that was intolerable, standing at the pump trickling gas into it, with a long line of cars waiting behind me.
So I drove it around until the gas light came on. Then I read various forum posts, and watched half a dozen YouTube videos on how to do the fix. Most of the videos are for older TJs, but mine is a 2005. The '05 and '06 have a different fuel pump and different gas line connectors. Between all of the videos I found enough info to remove the tank without breaking any connectors, and remove the fuel pump. It took about 1.5 hours to drop the tank.
I cleaned up the top of the tank, scraping it and using compressed air. Then I drove off the lock ring with a large ground-off screwdriver. That took another 45 minutes. After removing the fuel pump, I popped out the check valve. Sure enough, the float was sticking in the housing.
I filed the three sets of little dual tracks down about half way. Trying it in the housing, it was pretty free, but I filed a little more until it had some freeplay all the way up and down in the housing. I didn't want it to swell a little more and stick again.
After replacing the check valve in the tank, I installed a new Bosch 67756 fuel pump with sender (from Rock Auto, best price I could find). This is the identical fuel pump to the Mopar OEM one. My old pump was working fine, but at 100K miles I didn't want to have to drop the tank again soon if it died.
I installed the tank in the Jeep in another hour+. I turned on the key and let the pump run for a few seconds, until it sounded like it had pressured up the line, and then checked for leaks. Then it took another 10 or 20 seconds to crank it to life. No leaks, everything works right.
And I filled the tank with no slowdown, and no burp. Another Mopar screwup fixed. Wonderful.