Rajan Wilcox
Removing the fuel tank from a 2006 Durango involves several steps. Firstly, disconnect the fuel spout hose and pump out the fuel. Then, disconnect the electrical connector by pushing the red tab upward to unlock and pressing the black tab while removing. Next, disconnect the fuel line at the fuel pump module and the NVLD, ORVR, and evap lines at the front of the tank. Continue to lower the tank and remove the fuel pump module if necessary. When replacing the tank, ensure the fuel pump module is positioned correctly with the lockring tightened, and connect the evap, ORVR, and NVLD lines. Finally, connect the fuel line and raise the tank into position, securing it with straps.
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What You'll Learn
Disconnect the electrical connector
Disconnecting the electrical connector of a 2006 Durango fuel pump can be a tricky task. Here is a detailed, step-by-step guide to help you through the process:
First, locate the connector. It is usually positioned towards the front of the connector, close to the solenoid. You should see a small, red-coloured locking tab on it. This locking tab needs to be slid to the side, and then the connector should be pulled off. It might still need to push down or a pull up to disconnect, even after sliding the lock.
If the connector is being especially stubborn, it may be melted to the valve. In this case, you will need to use some force to disconnect it. However, be cautious when applying force, as you don't want to damage any other components.
Now, to physically disconnect the electrical connector, follow these steps carefully:
- Push upward on the red-coloured tab to unlock the connector.
- While removing the connector, push on the black-coloured tab.
- Disconnect the fuel line at the fuel pump module fitting. You can do this by pressing on the tabs at the side of the quick-connect fitting.
- Continue with the fuel tank removal process by disconnecting the NVLD, ORVR, and evap lines at the front of the tank.
Remember to take your time and be gentle during this process to avoid any damage to the electrical system or other components. Always refer to the manufacturer's guidelines or seek professional assistance if you are unsure about any steps.
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Disconnect the fuel line
Disconnecting the fuel line of a 2006 Durango requires careful attention to detail. Here is a step-by-step guide on how to do it:
Firstly, release the fuel system pressure. This is an important safety precaution to prevent any accidental spillage or injury. Next, drain the fuel tank to ensure no fuel remains in the system. Now, locate the rubber fuel vent hose at the tank fitting and loosen its clamp. Disconnect this hose carefully, ensuring that you do not damage the fitting or the hose itself.
At this point, you will need to support the fuel tank with a hydraulic jack to keep it stable and secure. Once the tank is supported, you can proceed to remove the two fuel tank strap bolts and both tank support straps. This will allow you to carefully lower the tank a few inches, providing better access for the next steps.
Now, you are ready to disconnect the fuel line. Locate the fuel pump module fitting, which is where the fuel line connects to the pump. You will see tabs at the side of this quick-connect fitting. Press on these tabs to disconnect the fuel line from the fuel pump module. It may require some force, but ensure you are only pressing on the tabs and not damaging any other components.
After disconnecting the fuel line, there are a few more steps to complete the fuel tank removal process. These include disconnecting the NVLD, ORVR, and evap lines at the front of the tank. Once these lines are disconnected, you can continue to lower the tank for complete removal. Remember to perform these tasks with caution and seek expert advice if needed.
Please note that working on fuel systems can be dangerous, and it is always recommended to consult a certified mechanic or seek professional assistance if you are unsure about any part of the process.
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Remove the lockring
To remove the lockring from a 2006 Durango fuel tank, you will need a Lockring Remover/Installer 9340 (3) and a 1/2 inch drive breaker bar (1).
First, you must drain and remove the fuel tank. Note the rotational position of the module before attempting removal. There is an indexing arrow located on top of the module for this purpose.
Next, position the Lockring Remover/Installer 9340 (3) into the notches on the outside edge of the lockring (5). Then, install the 1/2 inch drive breaker bar (1) into the Lockring Remover/Installer 9340 (3).
Now, rotate the breaker bar counterclockwise to remove the lockring. The module will spring up slightly once the lockring is removed. Be careful not to bend the float arm while removing the module from the fuel tank.
Finally, whenever the fuel pump module is serviced, remember that the rubber seal (gasket) must be replaced.
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Remove the fuel pump module
To remove the fuel pump module from a 2006 Durango, you must first disconnect the electrical connector. Do this by pushing upward on the red-coloured tab to unlock, then pushing on the black-coloured tab while removing the connector. Next, disconnect the fuel line at the fuel pump module fitting by pressing the tabs on the side of the quick-connect fitting.
Now, disconnect the NVLD, ORVR, and evap lines at the front of the tank. Continue to lower the tank for removal. If the fuel tank is to be replaced, remove the fuel pump module from the tank. Be sure to note the rotational position of the module before attempting removal. There is an indexing arrow located on top of the module for this purpose.
To remove the module, first position the Lockring Remover/Installer 9340 into the notches on the outside edge of the lockring. Install a 1/2 inch drive breaker bar into the Lockring Remover/Installer 9340. Rotate the breaker bar counterclockwise to remove the lockring. The module will spring up slightly when the lockring is removed. Carefully remove the module from the fuel tank, being careful not to bend the float arm.
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Position the fuel tank
To position the fuel tank of a 2006 Durango, follow these steps:
First, ensure that the fuel tank is empty. Pump out any remaining fuel if necessary. Disconnect the fuel spout hose and the fuel pump harness. Block up the rear of the tank with a 4"x4" piece of wood to prevent strain on the fuel and electrical connections. This will also allow you to access the tank from the side.
Next, position the fuel tank onto a hydraulic jack. Raise the tank until it is near the body of the vehicle. Connect the evap, ORVR, and NVLD lines at the front of the tank. Ensure that the fuel fitting on the top of the pump module is pointing towards the driver's side of the vehicle.
Then, connect the fuel pump module electrical connector at the top of the tank. Connect the fuel line quick-connect fitting to the pump module. Continue raising the tank until it is snug against the body. Install and position both tank support straps, and then install the two fuel tank strap bolts, tightening them to 30 ft-lbs (40 N.m).
Finally, connect the rubber fill and vent hoses to the fuel tank fittings and tighten the hose clamps. If equipped, install the fuel tank skid plate. Lower the vehicle and fill the fuel tank with fuel. Start the engine and check for any fuel leaks near the top of the module.
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Frequently asked questions
Push upward on the red-coloured tab to unlock, then push the black-coloured tab while removing the connector.
Disconnect the fuel line at the fuel pump module fitting by pressing on the tabs at the side of the quick-connect fitting.
After disconnecting the fuel pump harness, you can remove the straps and lower the tank.
You can lower the tank below the frame rail and access it from the side. Block up the rear of the tank with a 4"x4" piece of wood to avoid straining the fuel/electrical connections.
