Ameer Randolph
If you're looking to install a new fuel tank in your 1966 Mustang, you've come to the right place. In this guide, we'll walk you through the process step-by-step, from draining the old fuel tank to installing and sealing the new one. We'll also offer tips on tools to use, safety precautions, and common issues to look out for. By the end, you'll have the knowledge and confidence to tackle this project and get your Mustang running smoothly again.
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What You'll Learn
Prepare the workspace by jacking up the car and draining the fuel tank
To prepare your workspace for installing a new fuel tank in your 1966 Mustang, you will need to jack up your car and drain the fuel tank.
First, use a jack to lift your Mustang until you have enough space to work comfortably underneath it. You can use jack stands or a lift to hoist the car. It is recommended to have the rear of the car on jack stands and to block the front wheels.
Next, you will need to drain the fuel tank completely. Some Mustang fuel tanks have a small drain plug on the front passenger side that you can use. Alternatively, you can drain the fuel using the sending unit. If you are only replacing the sending unit, you can drain the fuel tank by removing the sending unit and using the drain plug.
Before draining the fuel, it is important to disconnect the hose from the fuel tank and remove the sending unit wire from the stud. Once the fuel is drained, you can proceed with the fuel tank installation process.
In addition to jacking up the car and draining the fuel tank, you may also need to remove items from your trunk to access the fuel tank and remove the bolts holding the tank in place. This preparation will ensure that you have adequate space and access to install the new fuel tank in your 1966 Mustang.
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Remove the fuel neck, hoses, and sending unit
Before you begin the process of removing the fuel neck, hoses, and sending unit, it is important to drain the fuel tank completely. This can be done using the drain plug or through the sending unit.
Now, you can start by removing the fuel neck, which is connected from the body of the car to the tank. Once the fuel neck is removed, move on to the hoses at the bottom of the tank, disconnecting them from the sending unit.
If you are planning to reuse the hoses, it is important to be careful during this step. Slice the hose on the fitting with a blade and then pull it off. If there is a retaining ring, you can remove it by hitting each tab a little with a screwdriver and hammer, tapping on each tab a little at a time.
With the hoses removed, you can now take out the sending unit. It is recommended to test the new sending unit before installing it. This can be done using a multimeter set to Ohms, grounding it anywhere on the chassis and pushing 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.
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Take out the bolts and screws holding the tank in place
To take out the bolts and screws holding the fuel tank in place, you will need to first move to your trunk and clear out any items or trim to allow you to access the fuel tank. Then, 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. Remove these bolts.
Next, 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 the tank while rotating the whole assembly. It should slide off. Now, twist the hose off the pipe and remove the filler pipe.
Note that you will be reusing the filler pipe when installing your new kit, but you will get a new filler pipe hose and gasket, so you can throw away the originals.
At this stage, you will have removed all the screws and bolts holding the tank in place. However, there is still 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.
Now, you can remove the fuel tank. Using your scraper, scrape off the original sealant on the edges of the fuel tank area to give yourself a clean area to apply new sealant to later.
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Clean the fuel tank area and apply primer and sealant
When removing the fuel tank from your 1966 Mustang, you will need to use a pry bar to loosen the sealant around the edges of the fuel tank from inside the trunk. Then, use a scraper to scrape off the original sealant on the edges of the fuel tank area. This will give you a clean area to apply the new sealant to later.
If there are any areas of bare metal showing after you have scraped off the sealant, apply a coat of primer to protect the metal from rust before installing the new fuel tank. You can use a product like RustBlast, which is a powerful rust remover, zinc phosphate pre-primer, and metal etch. It dissolves rust, corrosion, metal oxides, and tarnish from most metal surfaces.
Before installing the new fuel tank, apply strip caulk around the outside edge of the fuel tank area. This replicates the original equipment manufacturer (OEM) sealant. You can use 3M black strip body caulk, or a product like Gold Standard Tank Sealer, which will stop rust and form a tough, fuel-impervious coating.
It is important to note that you should be very careful when working with sealants and primers due to the environmental damage and the potential for harm to your eyes, hands, and clothes. Fumes can be very bad if not diluted, so you may need breathing equipment as a dust mask may not provide sufficient protection.
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Install the new fuel tank and test the sending unit
Before installing the new fuel tank, it is recommended to test the new sending unit. Using a multimeter set to Ohms, ground it anywhere on the chassis and push the positive on the stud. The reading should be anywhere from 70-80 Ohms. Next, move the float up to simulate the inside of the fuel tank.
Now, you can install the new fuel tank. First, move to your trunk and clear out any items or trim to allow you to access the fuel tank. Then, remove the twelve bolts holding the tank in place. Loosen the two screws on the clamps holding the filler pipe to the filler pipe seal. After that, remove the clamps, the gas cap, and the five bolts holding the filler pipe in place. Pull the filler pipe off of the tank while rotating the whole assembly and twist the hose off the pipe. You will need to reuse the filler pipe when installing your new kit, but you will get a new filler pipe hose and gasket.
Before installing the new fuel tank, apply a coat of primer to any areas of bare metal to protect it from rust. Then, apply strip caulk around the outside edge of the fuel tank area before installing the tank. This replicates the original sealant.
Finally, install the new fuel tank and test the sending unit. Put the sending unit in before the tank and ensure your float is brass, not plastic. Also, ensure you have a new retaining ring to hold the unit in place. If your stock "O" ring is flat, you may need to buy a regular "O" ring from a parts store. Additionally, when installing the new unit, put Vaseline on the rubber gasket between the tank and unit.
To test the sending unit, you can remove the front wheel and drive shaft to gain more access. If you are installing a new fuel line, you may need to remove the rear wheels and jack up the car and put it on jack stands.
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Frequently asked questions
First, jack up the car and put it on jack stands. Drain the fuel tank completely using the drain plug or through the sending unit. Remove the fuel neck connected from the body of the car to the tank. Disconnect the sending unit wire from the stud and then remove the hoses at the bottom of the tank where it connects to the sending unit. Remove the screws that hold the tank down and pull out the tank.
You will need a flat-blade screwdriver, a Phillips screwdriver, a hammer, a 3/8-inch ratchet, a 1/2-inch socket, a 3/8-inch socket, a 1/4-inch ratchet, a 7/16-inch socket, a 5/16-inch socket, a short extension, wire cutters, a pry bar, a 3/8-inch open-end wrench, a scraper, safety glasses, and a lift or jack and jack stands. You may also need a multimeter set to Ohms to test the new sending unit.
You should use caulking cord or strip caulk to seal your new fuel tank.
