Replacing the gas tank on your Jeep Cherokee is a simple project you can do yourself to save a costly repair bill. Rust, severe dents or leaking tanks are all candidates for replacement. The tank is located at the rear of the Jeep just under the cargo area. It is held in place using two steel straps that attach to the frame rails and pass under the tank, holding it snug against a set of mounts on the body. It can be helpful to have a second person on hand to balance the tank during removal and installation, but it can be done by yourself if you don't have help available.
Verify that your gas tank is empty, or drain the gas with a siphon hose before removing it.
Raise the rear of the Jeep with a floor jack placed under the rear differential. Support the Jeep on a set of jack stands under the rear axle tubes. Work on level, solid ground so the Jeep can not move.
Place a jack under the old tank to support it as you remove the bolts. Locate the two nuts on the J bolts on the front of the tank. Remove the nuts using a deep socket and ratchet or wrench. If the bolts are heavily rusted, you might need to cut them with a reciprocating saw and replace them.
Let the straps drop to the ground after the J bolts are removed and slowly start to lower the tank using the floor jack. On the front of the tank you will see the electrical connections and fuel lines that attach to the tank.
Remove the filler hose from the filler neck inlet on the tank using a screw driver to remove the hose clamp.
Remove the fuel lines from the tank. On older models you will need a screw driver to remove the hose clamps and remove the rubber hoses. On newer models you will need a tool to remove the fittings that can be purchased or rented at most auto parts stores.
Unplug the electrical connections that run from the Jeep body to the tank and lower the tank to the ground. Remove the tank from under the Jeep so you can remove the fuel pump and sender from the tank.
Locate the locking ring that holds the fuel tank sending unit and fuel pump in the tank. Remove it by turning it counterclockwise until it unlocks. Use a flat screw driver and a hammer to turn it, being careful not to damage it.
Remove the sender and pump from the tank and set it into the new tank, orienting it just as it was in the old tank. Install a new gasket and the locking ring to secure it.
Position the new tank under the Jeep and raise it with the jack until you can reinstall the fuel lines and electrical connections. Raise the tank the rest of the way and support it with the floor jack and a piece of wood.
Reinstall the filler neck hose to the inlet on the tank and secure with a hose clamp. Tighten it with a screwdriver, but do not over tighten the clamp as it will damage the rubber hose.
Raise the tank the rest of the way into the Jeep and install the tank support straps. Install the nuts onto the J bolts and tighten them until the straps are solidly supporting the tank. It should be tight, but do not tighten the nuts so much that you dent or crush the tank with the straps.
Place your jack under the rear differential housing and raise the Jeep off the jack stands. Remove the stands and lower the Jeep to the ground. Add fuel to the tank, check for any leaks and test run the Jeep.
