How to Install a Rugged Ridge Gas Tank Skid Plate 15/20 Gallon on your 1987-1995 Jeep Wrangler YJ

1. YJ 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. Remove the fuel filler assembly by first removing the 6 screws holding the filler neck in position. For easier access, remove two screws holding the license plate in place. Save these screws, they will be used to reinstall filler neck. NOTE: It is also possible to unhook filler hoses directly from gas tank.

3. Remove the nut from the bracket holding the exhaust pipe in place on the passenger side of the vehicle. This will allow movement in the exhaust pipe during removal of the tank from the vehicle.

4. Position oor jack centered beneath the gas tank. 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.

5. Using the oor jack, lower the gas tank approx 3 inches. Disconnect the electrical connector coming from the sending unit of the gas tank. Unhook the high pressure fuel line and the vent lines. Be careful not to allow any dirt or debris into the tank. NOTE: Have a bucket and some shop rags handy. Fuel may spill out when disconnecting fuel lines.

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 ller assembly making sure it doesn't snag on anything. Place the gas tank on the ground and remove the nuts holding the straps to the OE skid pan and remove the straps. Fit RR skid plate to vehicle without gas tank in place to make sure slots align with the vehicles mounting fasteners. NOTE: Earlier models YJ’s use only one metal strap to secure the gas tank to the skid plate. Later model YJ’s use two straps.

7. Locate the square cutouts in the RR skid plate and install the metal straps removed in step 6. Before fastening the straps, place the gas tank into the RR skid plate. Locate the proper slots in 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 oor jack under vehicle with gas tank assembly centered on top. Slowly raise into position being sure to guide filler assembly to its appropriate location. Stop about 3 inches away from the skid plates mounting position and reconnect fuel and vapor lines. Also reconnect the electrical connector before lifting into final position.

9. Lift gas tank assembly into final position. Angle the gas tank assembly so that the passenger side goes up first and avoids the exhaust pipe. Install the 7 nuts used to hold the OE skid pan into position. Hand tighten evenly for best fitment. Finally, tighten all nuts evenly to 17 ft-lbs.

10. Move filler assembly into its correct mounting position and insert the 6 torx head screws to secure the assembly to the vehicle. Install license plate back into position. On the passenger side of the vehicle, reinstall the bracket removed in step 3 to hold the exhaust pipe in place.

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.