Rajan Wilcox
If you're looking to install a fuel tank in a 1966 Mustang, you'll need to know about caulking. Fuel leaks can be dangerous and cause damage to your car, so it's important to get it right. This is a simple process that can be done by most home mechanics, but you'll need to make sure you have the right tools and materials. You'll need to drain the fuel tank, disconnect the fuel line, and remove the old tank before installing the new one. But before you do that, you'll want to apply strip caulk around the outside edge of the fuel tank area. This will act as a sealant and help to prevent leaks.
There are a variety of caulking materials available, including caulking cord, rope caulk, and adhesive-backed foam. You can find these at auto supply stores or online.
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What You'll Learn
Removing the old fuel tank
Drain the Fuel Tank
Before removing the fuel tank, it is essential to drain all the fuel from it. Use the drain plug or the sending unit to empty the tank completely. You can also siphon the fuel out by removing the rear seats, pulling out the pump, and inserting a siphon tube into the tank. Fill the tank with premium fuel to dilute the old stale gas, and then burn it off or dispose of it safely.
Disconnect the Fuel Line and Sending Unit
Disconnect the sending unit wire from the stud and detach the fuel line from the sending unit. Be sure to have a suitable container to catch any remaining fuel. You may also need to disconnect the main fuel line at the front and back and blow compressed air through to clean it out.
Remove the Filler Neck Hose and Retaining Screws
Loosen the hose clamps on the filler neck hose and break it loose from the tank. Then, remove the filler neck hose from the filler neck. Take out the retaining screws for the filler neck flange, which could include a 5/16 bolt that holds the top of the driver's side bumperette bracket.
Detach the Fuel Tank
With the fuel drained and the necessary components disconnected, you are now ready to remove the old fuel tank. The tank is held in place by a series of screws around its perimeter, which you will need to remove. Be cautious when breaking the seal, as it may require some force. Use a small 2x4 to slowly jack up the tank if it seems stuck, but be gentle to avoid damaging other components.
Clean and Prepare for Installation
Once the old fuel tank is removed, clean the trunk area with a wire brush. Prime and paint the area, and then apply a sealer. Ensure you have a new fuel tank and all the necessary hardware, such as bolts, a sending unit, a gasket, and fuel lines, if needed.
Remember to dispose of the old fuel and tank properly and follow all safety precautions when working with fuel and vehicles.
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Applying strip caulk
To apply strip caulk to a 1966 Mustang, follow these steps:
First, jack up the car until you're able to work comfortably underneath it. Drain the fuel tank completely using the drain plug or through the sending unit. Remove the sending unit wire from the stud and disconnect the hose from the fuel tank. Remove the gas cap and the nut inside the trunk that holds the don't-lose-me cable. Take out the filler neck hose from the filler neck and pull the filler neck out through the hole in the tail light panel.
Now, apply strip caulk around the outside edge of the fuel tank area. Ensure that the strip caulk is properly seated around all the edges. You can use a caulking cord or rope caulk, which is available at auto supply stores or online.
Once the caulk is in place, slide the new tank into position. Install and tighten the new hardware to lock the fuel tank in place.
It is important to note that some people have used alternative methods or materials instead of strip caulk. For example, one person used structural aluminum bracing and high-density adhesive-backed foam, while another used house caulking or Window Weld. However, strip caulk is recommended as it replicates the OEM sealant and makes tank removal easier in the future.
Additionally, before installing the new fuel tank, it is advisable to test the new sending unit using a multimeter. This ensures that the sending unit is functioning correctly.
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Installing the new fuel tank
Installing a new fuel tank in a 1966 Mustang is a relatively simple process that can be completed by most home mechanics. Here is a step-by-step guide on how to install a new fuel tank:
Drain the Old Fuel Tank
Before installing a new fuel tank, you must first drain the old fuel tank completely. Use suitable containers to collect the drained fuel. Remove the gas cap and then unplug the wire from the fuel sending unit. Disconnect the fuel line from the sending unit, and remove the hose from the fuel tank.
Remove the Old Fuel Tank
Remove the retaining screws for the filler neck flange and loosen the hose clamps on the filler neck hose. Break the filler neck hose loose from the tank and remove it from the filler neck. Pull the filler neck out through the hole in the tail light panel. Next, remove the sheet metal screws holding the tank to the car. There may also be a bolt on the driver's side bumperette bracket that holds the corner of the gas tank. With these removed, you can now pull out the old fuel tank.
Prepare the New Fuel Tank
Before installing the new fuel tank, test the new sending unit using a multimeter set to Ohms. Ground it anywhere on the chassis and push the positive on the stud. Move the float up to simulate the inside of the fuel tank and ensure the Ohms reading decreases as expected. Install the rubber ring onto the new fuel tank and then slide the sending unit into the hole, ensuring the stud is facing down. Install the metal ring and turn it a quarter turn by hand, then use a hammer and flathead screwdriver to secure it in place.
Install the New Fuel Tank
Apply strip caulk around the outside edge of the fuel tank area to replicate the OEM sealant. Slide the new fuel tank into place, ensuring the strip caulk is properly seated around all edges. Install and tighten the new hardware to lock the fuel tank in place.
Reattach Fuel Filler Pipe
Slide the new fuel filler pipe hose into place on the fuel tank and then slide the clamps over without tightening them. Slide the new gasket into place on the pipe and insert it through the hole for the gas cap. Slide the clamps into place on either end of the fuel filler pipe and tighten them down. Reinstall the bolts holding the fuel filler pipe and gas cap in place. Reconnect the fuel sending unit using a new clamp.
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Testing the new sending unit
Prepare the Multimeter:
Grab a multimeter and set it up to read ohms. The multimeter will be used to measure electrical resistance, which is crucial for testing the sending unit.
Ground the Negative Feed:
Locate the sending unit and ground the negative feed on it. You can do this by connecting the negative feed to any metal part of the sending unit or the fuel tank. This step ensures that you have a stable and safe electrical connection.
Connect the Positive Feed:
Place the positive feed on the sending unit stud. The sending unit stud is usually located at the top of the unit. If the unit is mounted upside down, the stud may be at the bottom, which corresponds to a full tank position.
Allow for Reading Adjustment:
Wait for a few seconds to let the multimeter reading adjust. The reading will vary depending on the specific sending unit you have. For example, on a 1983 Mustang, the reading should be around 73 ohms when empty and 10 ohms when full.
Interpret the Readings:
Once the wires are connected and the reading has stabilized, interpret the value. For instance, a reading of approximately 10 ohms indicates a full tank, while higher readings suggest a lower fuel level.
Inspect the Float:
Ensure that the float is installed correctly and is parallel to the bottom of the tank. Even a slight misalignment can affect the accuracy of the fuel gauge readings.
Verify Fuel Gauge Functionality:
With the sending unit connected, observe the fuel gauge. It should accurately reflect the fuel level in the tank. If the gauge reads past full or doesn't reach the full mark when the tank is full, adjustments may be needed.
Adjust the Sending Unit:
If the fuel gauge readings are inaccurate, minor adjustments to the sending unit may be required. This can involve bending the float arm slightly or adjusting the float height to ensure it is not hitting the side of the tank.
Test Fuel Gauge Response:
After making any necessary adjustments, test the fuel gauge response by adding fuel to the tank in small increments and observing the gauge readings. Ensure that the gauge accurately reflects the fuel level, especially at empty, half, and full marks.
Finalize Installation:
Once you are satisfied with the accuracy of the sending unit and fuel gauge, finalize the installation by securing the sending unit in place and ensuring all connections are tight and sealed.
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Reattaching the fuel filler pipe
Now, install and tighten down the new hardware to lock the fuel tank into place. Slide the new fuel filler pipe hose into place on the fuel tank. Then, slide the two clamps over the new hose without tightening them. Before installing the fuel filler pipe, slide the new gasket into place on the pipe. Then, insert it through the hole where the gas cap covers and into the fuel filler pipe hose.
Now, slide the two clamps into place on either end of the fuel filler pipe hose and tighten them down. Reinstall the four bolts holding the fuel filler pipe in place and the one for the gas cap. While under the car, reconnect the fuel sending unit using a new clamp to replace the old one.
Finally, put some fresh fuel in the tank and check everything for leaks before taking it for a test drive. Installation should only take around an hour.
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Frequently asked questions
First, drain the gas from the tank. Then, apply strip caulk around the outside edge of the fuel tank area. Slide the new tank into place and ensure the strip caulk is properly seated around all of the edges. Install and tighten down the new hardware to lock the fuel tank into place.
The type of caulk you should use is called strip caulk. It is available at NPD, NAPA, Amazon, Ace Hardware & Home Centre, and Virginia Mustang.
First, drain the gas from the tank. Then, remove the fuel neck connected from the body of the car to the tank. Disconnect the hose from the sending unit and remove the gas cap. Next, remove the four retaining screws for the filler neck flange and loosen the two hose clamps on the filler neck hose. Finally, break the filler neck hose loose from the tank and pull the filler neck out through the hole in the tail light panel.
