Fuel Tank Strap

Remove and replace the fuel tank mounting straps on a 1966 Chevrolet Corvette, requiring fuel tank lowering and strap replacement.

Warnings

Tools required

Parts

• Fuel tank strap (left) × 1 — Use OEM specification
• Fuel tank strap (right) × 1 — Use OEM specification
• Fuel tank strap mounting bolts × 4 — 1/2 inch-13 x 1.5 inch
• Fuel tank insulator pads × 2 — Use OEM specification

Preparation

1. Park vehicle on level concrete surface in well-ventilated area away from ignition sources
2. Place fire extinguisher within immediate reach of work area
3. Disconnect negative battery cable to prevent electrical sparks
4. If fuel level is above 1/4 tank, siphon fuel using manual siphon pump into approved fuel storage containers until tank is near empty or contains less than 5 gallons
5. Allow vehicle to sit for 15 minutes with windows open to allow fuel vapors to dissipate
6. Raise rear of vehicle using floor jack at rear differential housing and support with jack stands under frame rails behind differential
7. Raise front of vehicle and support with jack stands under front frame rails to achieve level working position
8. Remove rear wheels for improved access (optional but recommended)
9. Position fuel catch pan under fuel tank area

Procedure

1. 1

   Disconnect fuel filler neck hose
   Locate the fuel filler neck hose connecting the filler tube to the tank at the center rear of the vehicle. Loosen the hose clamp securing the filler neck hose to the tank using a flathead screwdriver or 1/2 inch socket. Gently twist and pull the hose off the tank inlet neck. Be prepared for residual fuel spillage.
2. 2

   Disconnect fuel vent line
   Locate the smaller diameter vent line connected to the top of the fuel tank near the filler neck. This is typically a 3/8 inch rubber hose secured with a spring clamp. Release the clamp and disconnect the vent line from the tank fitting. Cap or plug the line to prevent fuel vapor escape.
3. 3

   Disconnect fuel sender electrical connector
   Locate the fuel sender unit on top of the tank (accessible from under the vehicle). Disconnect the electrical connector from the fuel sender by pulling the connector apart. On 1966 models, this is typically a single-terminal push-on connector with the sender grounding through the tank/chassis.
4. 4

   Disconnect fuel outlet line
   Locate the main fuel outlet line at the front of the fuel tank, typically a 3/8 inch steel line with a flare fitting. Using a 9/16 inch wrench on the line fitting and a 9/16 inch wrench on the tank fitting, loosen and disconnect the fuel line. Be prepared for fuel spillage into the catch pan. Plug the line with a rubber cap to prevent fuel drip.
5. 5

   Position tank support jack
   Position a transmission jack or floor jack with a wide wood block (minimum 12 inches x 12 inches) under the center of the fuel tank. Raise the jack until it just contacts the tank bottom and provides light support, but does not lift the tank. The tank should remain resting on the straps with the jack providing safety support only.
6. 6

   Remove driver side fuel tank strap
   Locate the driver side fuel tank strap mounting bolts at the front and rear of the strap where it attaches to the frame crossmember. Using a 9/16 inch socket and ratchet, remove the 2 mounting bolts securing the driver side strap. If bolts are severely corroded, apply penetrating oil and allow to soak for 10 minutes. Once bolts are removed, carefully lower the strap away from the tank while supporting the tank with the jack.
7. 7

   Remove passenger side fuel tank strap
   Locate the passenger side fuel tank strap mounting bolts at the front and rear attachment points to the frame crossmember. Using a 9/16 inch socket and ratchet, remove the 2 mounting bolts securing the passenger side strap. As you remove the final bolt, ensure the jack is securely supporting the tank weight. Once bolts are removed, carefully lower and remove the strap.
8. 8

   Lower and inspect fuel tank
   With both straps removed, slowly lower the transmission jack to drop the tank approximately 6 inches. This provides clearance to inspect the tank top, strap condition, and insulator pads. Do not fully remove the tank unless necessary for additional repairs. Inspect the tank mounting surface for rust, debris, or damage.
9. 9

   Remove and inspect old strap components
   Remove the old fuel tank straps completely and inspect for cracks, excessive rust, or deformation. Remove the rubber insulator pads from the top of the tank where the straps contacted the tank body. These pads prevent metal-to-metal contact and should be replaced if compressed, cracked, or deteriorated.
10. 10

    Clean mounting surfaces
    Using a wire brush, clean the frame crossmember mounting points where the strap bolts attach. Remove rust, dirt, and old thread locker. Clean the top surface of the fuel tank where the insulator pads sit, removing any rust or debris to ensure proper strap seating.
11. 11

    Install new insulator pads
    Position the new rubber insulator pads on top of the fuel tank at the locations where the straps will contact the tank body. There are typically 2 pads, one on each side of the tank corresponding to the strap positions. Ensure pads are centered and will not shift during strap installation.
12. 12

    Raise tank to installation position
    Using the transmission jack, slowly raise the fuel tank until it is positioned at the correct height with the insulator pads compressed slightly between the tank and frame. The tank should be level and centered between the frame rails. Hold this position for strap installation.
13. 13

    Install passenger side fuel tank strap
    Position the new passenger side fuel tank strap over the tank and align the strap ends with the mounting holes in the frame crossmember. Insert the 2 mounting bolts (1/2 inch-13) through the strap and thread into the frame crossmember. Hand tighten both bolts but do not fully tighten yet.
14. 14

    Install driver side fuel tank strap
    Position the new driver side fuel tank strap over the tank and align the strap ends with the mounting holes in the frame crossmember. Insert the 2 mounting bolts (1/2 inch-13) through the strap and thread into the frame crossmember. Hand tighten both bolts but do not fully tighten yet. Verify the tank is centered and level before final tightening.
15. 15

    Torque strap mounting bolts
    Using a 9/16 inch socket and torque wrench, tighten all 4 fuel tank strap mounting bolts to 25-30 ft-lbs in a cross pattern (alternate between driver and passenger side). Ensure straps are evenly tensioned and the tank does not shift during tightening. Remove the transmission jack once straps are fully tightened.
16. 16

    Reconnect fuel outlet line
    Remove the plug from the fuel outlet line and reconnect the 3/8 inch fuel line to the tank outlet fitting. Using two 9/16 inch wrenches, tighten the flare fitting securely. Ensure the line is routed correctly and does not contact the exhaust or suspension components.
17. 17

    Reconnect fuel sender electrical connector
    Reconnect the electrical connector to the fuel sender unit on top of the tank. Ensure the connection is secure and the terminals are fully seated. Verify the wiring harness is routed away from sharp edges and heat sources.
18. 18

    Reconnect fuel vent line
    Remove any plug from the vent line and reconnect the vent line to the tank fitting. Secure the line with the spring clamp or hose clamp, ensuring a tight seal to prevent fuel vapor leaks.
19. 19

    Reconnect fuel filler neck hose
    Slide the fuel filler neck hose onto the tank inlet neck, ensuring it is fully seated (minimum 2 inches of overlap). Tighten the hose clamp securely using a flathead screwdriver or 1/2 inch socket. Verify the hose is not kinked or twisted.

Reassembly

1. Reinstall rear wheels if removed and torque lug nuts to specification
2. Reconnect negative battery cable
3. Add fuel to tank if it was drained below operating level
4. Check all fuel line connections for proper seating before starting engine

Verification

• With vehicle still on jack stands, turn ignition key to ON position (do not start engine) and listen for fuel pump operation for 2-3 seconds
• Inspect all fuel line connections, filler neck, and vent line for fuel leaks while pump is running
• Start engine and allow to idle for 5 minutes while inspecting under vehicle for any fuel drips or leaks
• Verify fuel gauge operates correctly indicating proper fuel sender connection
• Check that fuel tank does not sag or shift and straps are holding tank securely in position
• After test drive, re-inspect all connections and strap bolts for leaks or loosening

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