How hard to replace gas tank and all associated hardware?

[84 400]

Another good tip for those wanting to clean there tank is to use a length of chain inside as it will loosen any rust or crud build up.

[D-Day]

Should I use any sealant putting the sending unit in, or just the rubber ring that comes with it?

[asphaltburner]

Yo! Just the rubber ring. Rotate the locking ring with a hammer and punch until it's in it's locked position. Todd.

[D-Day]

Excellente...

I picked up a can of Permatex rust treatment. I'm gonna dig up a big box, and a garbage bag, put the brackets in and bug bomb them mercilessly. Need to paint warm, so I'll do it in the house. I'll use the box and bag for my own little paint shop to keep the fumes in there.

[D-Day]

Slight predicament...the vent outlet on the tank is bigger than the other one, and the hose that fits it will not fit the vent outlet on the filler neck (hose too big).

I'm pinching pennies, is there a way I could just notch the rubber and clamp it extremely tight? It's just a vent, not the actual filler hose.

If not, does the auto store have a big enough adapter for this? Yeah, lazy question, but pinching pennies. If it wasn't a financial matter, I wouldn't be asking. Plus, I'm tired of trips to the store...

[BLE 'BURBAN]

Run both hoses down to napa and pick up a reducer to join the two together by splicing them in the middle.
1 reducer 2 clamps 1 knife done deal

[D-Day]

After all that...NOTHING.

All hoses, lines, wires, everything hooked up, I still have the sucking air problem. I took the line off at the regulator and blew it out, nothing blocking it as far as I can tell. I even took the line off completely, turned the pump on, NOTHING. I know nothing is blocking it, because I just replaced every damn thing there is.

The only thing I have left that I can think of doing anything is the tank selector. I'm gonna go pick up a connector to connect fuel lines, and I'm gonna go connect it directly to the tank to the pump. If it doesn't work then...

My guess would be maybe something in the tank selector switch in the cab is messed up, and it's not switching it. I don't know why, because when I switch it, it registers that tank as having gas in it, because something is switching. I'm just not sure if it's physically switching inside the unit. Which, by the way, is also BRAND NEW.

Bah.

[D-Day]

Oh my God...you're not gonna believe this.

I was under there trying to siphon some gas from the tank, with my mouth for the record (desperate times call for desperate measures), to make sure it was pulling through, and when some started to come through, I hooked it to the pump...it blew it out.

I grabbed the flashlight and moved it to the bottom of the electric fuel pump so fast I almost broke my arm. And what should I see... IN - OUT...reversed. Even though I had mounted an identical model pump in the exact same configuration, every time I was under there I did it in low light and failed to notice the bottom of the pump.

Since, naturally it could be assumed that if it was mounted the same way before, it'd work this way, right?

WRONG.

For some reason, the pump they gave me must have been configured for a driver side frame rail placement, either that or my old one was for the passenger side, or whatever. Bottom line: The pump was blowing, not sucking.

So...I replaced everything but the pump for nothing.

Oh well. I'm glad everything is replaced in retrospect...but what a price for stupidity.