How to Install a Rugged Ridge Gas Tank Skid Plate on your 1997-2006 Jeep Wrangler TJ

1. TJ Gas Tank Skid Plate (1)

NOTE: Perform installation when gas gauge reads below 1/4 tank. A lighter gas tank will be easier to manage. Also, have a partner handy to assist with the removal and installation of the tank.

WARNING: When working near gasoline, always be cautious not to have any heat or flame generating device as this could result in combustion and cause injury or death. Always keep a fire extinguisher handy when working with combustible fluids.

1. Disconnect battery terminals before beginning installation of this product. Disconnect negative terminal first making sure not to contact the positive terminal with the tool being used.

2. Remove the gas cap from the vehicle to relieve the pressure inside the tank. Cut zip ties holding axle vent tubes to the filler hose. To gain access to these tubes, remove the plastic cover from underneath the rear quarter panel. Remove the fuel filler assembly by first removing the 4 screws holding the filler neck in position. Next, remove the 4 screws holding the plastic bezel. Save these screws, they will be used to reinstall filler neck. NOTE: Instead of removing the complete filler assembly, filler and overow hoses can be removed directly from the tank by loosening the clamps securing them.

3. Some TJ models will have a grounding strap attached to the driver’s side shock mount. Use a flat head screwdriver to remove it. Disconnect the electrical connector on top of the gas tank by sliding the red clip to the side and unlocking the connector. Also disconnect the evaporation hose and high pressure line from the metal tubing at the left front corner of the tank. NOTE: Have a bucket and some shop rags handy. Fuel may spill out when disconnecting fuel lines.

4. Position floor jack centered beneath the gas tank to hold it in place. Remove the 7 nuts holding the gas tank and the OE skid pan to the vehicle. Save these nuts as they will be used to reinstall the gas tank. Do not remove the nuts securing the gas tank to the OE skid pan straps untill the gas tank is on the ground.

5. Late model jeeps will have the fuel rail connected to the top of the tank. Using the floor jack, lower the gas tank approx 3 inches. Unhook the fuel rail from the top of the tank and disconnect the vent hose from the rollover valve at the back right corner of the tank.

6. Once all lines and wires are disconnected from the gas tank, proceed to lower and completely remove the tank from the vehicle. Be sure to guide the filler assembly making sure it doesn't snag on anything. Place the gas tank on the ground. Fit RR skid plate to vehicle without gas tank in place to make sure slots align with the vehicles mounting fasteners. 

7. Remove the nuts holding the straps to the OE skid pan. Reinstall these straps in the RR skid plate using the square cutouts in the front of the pan. Remove gas tank from OE skid pan and place into the RR skid plate. Locate the proper slots in the rear of the RR skid plate for each straps threaded stud. Tighten the nuts onto the studs to secure the gas tank to the RR skid plate. Be careful not to over tighten these bolts.

8. Position floor jack under vehicle with gas tank assembly centered on top. Slowly raise into position being sure to guide filler assembly to its appropriate location. The gas tank assembly may need to be tilted back to avoid the rear track bar when lifting. Stop about 3 inches away from the skid plates mounting position and reconnect the fuel rail to the top of the tank. It may be easier to reconnect the vent tube to the rollover valve and the electrical connector at this time also. 

9. Resume lifting the gas tank assembly slowly into position. Line up factory mounting studs with the slots in the skid plate. Tighten the 7 nuts onto the factory studs evenly to 17 ft-lbs to secure gas tank assembly into position. Reconnect the high pressure fuel line, evaporation hose, and electrical connector (if not already connected in step 8).

10. Locate 2 axle vent hoses and zip tie hoses to fuel filler neck. Also, reconnect the grounding strap to the driver side shock mount if applicable. Hold filler neck in position and reinstall 8 screws to secure the filler assembly to the vehicle. Reconnect the fuel filler and overow hoses to the tank if they were detached prior to lowering the tank.

11. Reconnect vehicle wires to the battery terminals. Attach negative terminal wires last. Once all wires are connected and installation is complete, start engine. You may need to pump the gas pedal a few times to get fuel through the lines and to the engine. Once started, check all fuel lines for leaks.