Regan Brown
If you're looking to replace your 1966 Mustang's fuel tank, you've come to the right place. This article will guide you through the process, from draining the old tank to installing and sealing the new one. We'll also cover the replacement of the fuel tank sending unit, which is compatible with all 1965-1968 Mustang models. By following these steps, you'll be able to restore your classic Mustang and get back on the road in no time!
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What You'll Learn
Drain the fuel tank
To drain the fuel tank of a 1966 Mustang, you can try the following methods:
Using the Drain Plug
First, check if your Mustang has a drain plug. Some factory tanks have a drain plug in one corner that you can pull to drain the tank. However, it may be rusted in place, especially if the car has been sitting for a long time. If the drain plug is stuck, you can try using PB Blaster to loosen it. Be careful not to use heat around the fuel tank, as it could be dangerous.
Disconnecting the Hose
If you don't have a drain plug or it's stuck, you can try disconnecting the hose from the sending unit or the fuel tank. Place a container underneath to catch the fuel. You can also try using a suction hose to help with the draining process.
Siphoning the Fuel
Another method is to siphon the fuel out through the filler neck. Jack up the rear end of the car and place it on jack stands. Remove the gas cap to relieve the pressure in the tank, then remove the flexible hose at the gas tank. Attach a 3-foot length of fuel line to the filler neck and place the other end in an empty container to catch the fuel.
Using the Fuel Pump
You can also try using the fuel pump to drain the tank. Disconnect the fuel line at the carburettor and use a piece of fuel line to connect the fuel pump to a gasoline container. Start the engine, and the fuel pump will pump the gas into the container.
Replacing the Tank
If you're replacing the fuel tank, it's recommended to install the sending unit first. Make sure you have a new sender, some heavy grease, and a hammer. Coat the O-ring with grease or a sticky substance like Vaseline to hold it in place. Install the gasket and metal retaining ring, then tap them into place with a screwdriver and hammer.
Once you've drained the fuel tank, you can proceed with the rest of the fuel tank replacement process. Remember to work carefully and safely, especially when dealing with flammable liquids and electrical components.
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Disconnect the fuel line
Disconnecting the fuel line of a 1966 Mustang can be a challenging task. Before beginning, it is important to have the car jacked up securely and to drain the fuel tank completely.
One of the most important tools for this job is a quick-disconnect tool, which can be purchased cheaply from most auto parts stores. This tool can make the job much faster and easier. If you do not have access to a quick-disconnect tool, a hose clamp adjusted to the correct diameter can be used as a substitute.
To disconnect the fuel line, first locate the hose connected to the fuel tank. You may need to remove the fuel neck connecting the tank to the body of the car. Once the hose is located, use the quick-disconnect tool or hose clamp to disconnect it from the fuel tank. Be sure to get the tool under the spring that is in the line, and twist and turn as you insert. This process may require some patience and persistence.
After the hose is disconnected, there may be some residual sealant or grime that needs to be cleaned off. It is important to scrape this away to prepare for the new sealant that will be applied when the new fuel tank is installed.
In addition to the hose, there are also screws and clamps that hold the fuel tank in place. These will need to be removed as well. First, remove the gas cap and locate the bolts holding the filler pipe in place. There are typically four bolts underneath the gas cap and one on the inside of the trunk. Loosen the screws on the clamps holding the filler pipe to the filler pipe seal, and then remove the clamps and bolts. Pull the filler pipe off the tank and twist the hose off the pipe. Now you can remove the entire fuel tank assembly.
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Remove the fuel neck
To remove the fuel neck of a 1966 Mustang, you will first need to drain the gas from the tank. You can do this by using the drain plug or through the sending unit. Once the tank is empty, you can begin to remove the fuel neck.
First, unplug the wire from the fuel sending unit and disconnect the fuel line from the sending unit. Next, remove the gas cap and locate the four bolts holding the filler pipe in place. There will be one bolt inside the trunk, behind the filler neck, that holds the don't-lose-me cable onto the car. Remove these bolts.
Now, loosen the two screws on the clamps holding the filler pipe to the filler pipe seal and then remove the clamps. Pull the filler pipe off of the tank and twist the hose off the pipe. You can now remove the filler neck hose from the filler neck and pull the filler neck out through the hole in the tail light panel.
It is important to note that you will reuse the filler pipe when installing a new fuel tank, but you should get a new filler pipe hose and gasket. Additionally, you may need to scrape off old sealant and apply a coat of primer to protect the bare metal from rust before installing a new fuel tank.
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Remove the bolts holding the tank in place
To remove the bolts holding the fuel tank in place, you must first ensure you have drained the tank of gas. You can do this by using the drain plug or through the sending unit. Disconnect the hose from the fuel tank and remove the sending unit wire from the stud.
Now, move to your trunk and clear out any items or trim to allow you to access the fuel tank. You will then need to remove the bolts holding the tank in place. There are twelve bolts in total. First, remove the gas cap and locate the five bolts holding the filler pipe in place. There are four bolts underneath the gas cap and one on the inside of the trunk. Loosen the two screws on the clamps holding the filler pipe to the filler pipe seal, and then remove the clamps and the bolts.
Pull the filler pipe off of the tank, twisting the hose off the pipe and removing the filler pipe. There is also a nut inside the trunk, behind the filler neck, that holds the don't-lose-me cable onto the car, which should be removed.
Even after removing the bolts, there may still be some sealant holding the tank in place. Use a pry bar to loosen the sealant around the edges of the fuel tank from inside the trunk. You can then remove the fuel tank.
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Prepare the new tank and seal
To prepare the new tank and seal for your 1966 Mustang, follow these steps:
Firstly, drain the fuel tank completely. Use the drain plug or the sending unit to do this. Next, remove the sending unit wire from the stud and disconnect the hose from the fuel tank. Now, move to the trunk and clear out any items or trim to access the fuel tank. Loosen the two screws on the clamps holding the filler pipe to the filler pipe seal. Remove the clamps, the gas cap, and then the five bolts holding the filler pipe in place. Pull the filler pipe off the tank and twist the hose off the pipe.
Now, you will need to remove the fuel tank. Use a pry bar to loosen the sealant around the edges of the fuel tank from inside the trunk. Scrape off the original sealant on the edges of the fuel tank area to give yourself a clean area to apply the new sealant. If there are any areas of bare metal showing, apply a coat of primer to protect the metal from rust before installing the new fuel tank.
Apply strip caulk around the outside edge of the fuel tank area before installing the new tank. This replicates the OEM sealant. It is also a good idea to test the new sending unit before installing the tank. Use a multimeter set to Ohms, ground it anywhere on the chassis and push the positive on the stud. You should see a reading of 70-80 Ohms. Move the float up to simulate the inside of the fuel tank.
Before installing the new tank, ensure you have a new sending unit and that your float is brass, not plastic. Also, ensure you have a new retaining ring to hold the unit in place. You can now install the new tank, following the above steps in reverse.
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Frequently asked questions
First, drain the gas from the tank. Then, remove the gas cap and the filler neck hose. Disconnect the wire from the fuel sending unit and the fuel line from the sending unit. Remove the retaining screws for the filler neck flange and the sheet metal screws holding the tank to the car. Finally, pull out the old tank.
Before installing a new fuel tank, test the new sending unit. Using your multimeter set to Ohms, ground it anywhere on the chassis and push the positive on the stud. You should see anywhere from 70-80 Ohms. Then, move the float up to simulate the inside of the fuel tank.
You should use strip caulk to seal your new fuel tank. This is available at your local NAPA.
Make sure you put the sending unit in first before the tank. Also, ensure that your float is brass, not plastic, and have a new retaining ring to the unit in place.
