Hawklord Posted October 25, 2021 Share Posted October 25, 2021 Has anyone got any tips on how to get the fuel tank out of a 300TDI Defender 90. I have removed all 6 bolts and the front mounting bracket and the tank is free to move but the gap between the chassis rail and outer sill rail doesn't seem to be wide enough to get it out. Is there a special way to angle the tank to allow it to be removed. There is an outer sill rail bolted to the floor, does that have to be removed ?. I don't want to hammer it out as I cant hammer in the new tank. Any advice would be much appreciated. Quote Link to comment Share on other sites More sharing options...
simonpelly Posted October 25, 2021 Share Posted October 25, 2021 Can't help you with the 90 as I've only done this on a 110. No doubt you've drained all the fuel first though 🙂 Simon... Quote Link to comment Share on other sites More sharing options...
Hawklord Posted October 25, 2021 Author Share Posted October 25, 2021 Yes all fuel has been drained 👍, just haven't yet found a way to get the tank out 😒 Quote Link to comment Share on other sites More sharing options...
Geojake Posted October 25, 2021 Share Posted October 25, 2021 Hammer out the old tank!! For some reason, getting a new one in is easier than getting the old one out, from my experience. I managed to squeeze the new one in with a bit of crowbarring. Jake Quote Link to comment Share on other sites More sharing options...
simonb Posted October 25, 2021 Share Posted October 25, 2021 (edited) You may need to remove the frame that runs from the bulkhead to the rear of the seatbox/door pillar - under the door edge of the floor. Edited October 25, 2021 by simonb Quote Link to comment Share on other sites More sharing options...
Hawklord Posted October 25, 2021 Author Share Posted October 25, 2021 19 minutes ago, simonb said: You may need to remove the frame that runs from the bulkhead to the rear of the seatbox/door pillar - under the door edge of the floor. That is what I am now thinking as this is what the tank seems to be fouling on. Quote Link to comment Share on other sites More sharing options...
pete3000 Posted October 25, 2021 Share Posted October 25, 2021 I've done this job, it's a pig. remove or loosen the sill bolts and the upright bolts x2 into the seatbox. The other "fun part" is re attaching the filler and breather pipes through the wheelarch. Pete Quote Link to comment Share on other sites More sharing options...
Litch Posted October 25, 2021 Share Posted October 25, 2021 Can't see the difficulty, mine fitted into position easily......... 😆 1 2 Quote Link to comment Share on other sites More sharing options...
pete3000 Posted October 25, 2021 Share Posted October 25, 2021 that's cheating, lol. Quote Link to comment Share on other sites More sharing options...
monkie Posted October 25, 2021 Share Posted October 25, 2021 1 hour ago, Litch said: Can't see the difficulty, mine fitted into position easily......... 😆 Im glad I have a 110 if that is the extent you need to go to remove the fuel tank from a 90😊 Quote Link to comment Share on other sites More sharing options...
Hawklord Posted October 26, 2021 Author Share Posted October 26, 2021 14 hours ago, pete3000 said: I've done this job, it's a pig. remove or loosen the sill bolts and the upright bolts x2 into the seatbox. The other "fun part" is re attaching the filler and breather pipes through the wheelarch. Pete I removed the sill and the tank dropped out 😊 Thanks all for the advice given. Quote Link to comment Share on other sites More sharing options...
pete3000 Posted October 26, 2021 Share Posted October 26, 2021 8 hours ago, Hawklord said: I removed the sill and the tank dropped out 😊 Thanks all for the advice given. no problem, it wasn't even my 90 i volunteered to help with. Mind you similar levels of fun can be had trying to remove and fit older 110 tanks without removing the sender/pickup first Quote Link to comment Share on other sites More sharing options...
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