Fuel Tank Strap

Remove and replace the fuel tank mounting straps on a 2008 Dodge Viper, requiring fuel tank lowering and exhaust component removal.

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 — Use OEM specification
• Exhaust flange gasket (if reused hardware is worn) × 1 — Use OEM specification

Preparation

1. Park vehicle on level, solid surface with adequate ventilation. Engage parking brake.
2. Disconnect negative battery cable and isolate it away from battery terminal to prevent electrical sparks.
3. Relieve fuel system pressure: Remove fuel filler cap. Locate fuel pump relay in power distribution center and remove it. Attempt to start engine; it should run briefly then stall. Crank engine for 5 seconds to ensure pressure is released.
4. If fuel tank is more than 1/4 full, use approved siphon pump to drain fuel into approved containers. Never siphon fuel by mouth.
5. Raise vehicle on lift or with floor jack and support securely on jack stands at manufacturer-specified lift points. Vehicle must be high enough to allow transmission jack clearance under fuel tank.
6. Place fire extinguisher within immediate reach of work area.
7. Allow exhaust system to cool completely if vehicle was recently driven (minimum 1 hour cool-down).

Procedure

1. 1

   Access fuel tank from underneath
   Position yourself under the vehicle rear section. Locate the fuel tank mounted in the rear structure of the vehicle; on the Viper the tank is positioned in the rear chassis area near the rear transaxle/differential. Verify exact location against the factory service manual for the ZB Viper chassis. Identify the two fuel tank straps that wrap under the tank and bolt to the frame on each side. Note the routing of fuel filler hose, vent lines, fuel supply/return lines, and electrical connector to fuel pump module on top of tank.
2. 2

   Disconnect exhaust system at mid-pipe
   Verify whether exhaust removal is required for fuel tank strap access on the 2008 Viper, which uses a side-exit exhaust system. If exhaust disconnection is necessary, locate the correct flange connection per the factory service manual before applying penetrating oil and removing bolts. Apply penetrating oil to the flange bolts and allow to soak for 5-10 minutes. Remove the flange bolts connecting the exhaust sections. Support the rear exhaust section and carefully lower or move it aside to provide clearance for fuel tank removal. The exhaust may rest on the rear axle or suspension components temporarily.
3. 3

   Disconnect fuel filler hose and vent lines
   At the fuel tank filler neck area, locate the fuel filler hose connecting the filler neck to the tank. Confirm the filler side against the factory service manual before proceeding. Loosen and remove the hose clamp securing the filler hose to the tank inlet. Carefully twist and pull the filler hose off the tank inlet. Locate the vent lines (typically smaller diameter rubber hoses) connected near the filler neck area. Note their routing for reinstallation. Loosen clamps and disconnect vent lines from tank.
4. 4

   Disconnect electrical connector
   Locate the fuel pump module electrical connector on top of the fuel tank. Press the locking tab or release mechanism and disconnect the electrical connector. Move the harness aside and secure it away from the tank so it will not interfere with lowering.
5. 5

   Disconnect fuel supply and return lines
   Locate the fuel supply and return hard lines that connect to the fuel pump module on top of the tank. These are quick-connect style fittings. Place a shop rag around each connection to catch residual fuel. Using the appropriate size fuel line disconnect tool, insert the tool into the quick-connect fitting and pull the line straight off. Cap or plug the open lines if available to prevent contamination. Expect some fuel spillage.
6. 6

   Support fuel tank with transmission jack
   Position transmission jack or adjustable jack with a large wooden block (minimum 12x12 inches) under the center of the fuel tank. Raise jack until it just contacts the tank bottom and provides firm support. The tank should be securely supported but not bearing the jack's lifting force yet. Verify the jack is centered and stable.
7. 7

   Remove fuel tank strap mounting bolts
   Locate the fuel tank strap mounting bolts at the front and rear ends of each strap where they attach to the frame. The number of bolts per strap must be verified against the factory service manual for the 2008 Viper; do not assume a specific count until confirmed. Apply penetrating oil if bolts show corrosion. Using a socket and wrench, remove all 4 strap mounting bolts. Support the straps as you remove the final bolts to prevent them from falling.
8. 8

   Remove fuel tank straps
   With all mounting bolts removed, carefully pull the fuel tank straps away from the tank and down. The straps may be stuck to the tank due to rubber isolators or corrosion. Work them free carefully. Remove both straps completely and set aside. Inspect the straps for damage, excessive rust, or deformation.
9. 9

   Lower fuel tank slightly for clearance
   With straps removed and tank supported on jack, carefully lower the jack 2-4 inches to create working clearance. Do not lower the tank completely unless replacement of additional components is planned. Verify all lines and electrical connectors are truly disconnected and will not be damaged as tank is lowered. The tank should remain stable on the jack platform.
10. 10

    Inspect tank mounting area and install new straps
    Inspect the fuel tank exterior for damage, corrosion, or leaks. Check the frame mounting points where straps attach for rust or damage. Clean mounting surfaces with wire brush if needed. Position the new fuel tank straps around the tank in the same orientation as the original straps. The straps should have rubber or cushioned sections that contact the tank to prevent chafing. Ensure any isolators or cushions are properly positioned.
11. 11

    Raise tank and align strap mounting holes
    Carefully raise the transmission jack to lift the fuel tank back to its normal installed position. As the tank rises, guide the strap ends toward their frame mounting points. Align the strap mounting holes with the threaded holes or bolt holes in the frame. This may require repositioning the straps or slight tank position adjustment. Have an assistant help support and align components if possible.
12. 12

    Install and tighten strap mounting bolts
    Install all 4 fuel tank strap mounting bolts (2 per strap) and thread them in by hand first to verify proper alignment. Tighten the bolts in a cross pattern (alternating front-to-rear, left-to-right) to evenly load the straps. Tighten bolts firmly to secure the tank, typically to a snug fit plus additional torque. Tighten the fuel tank strap mounting bolts to the factory-specified torque from the 2008 Viper service manual. Do not guess the value; verify the spec before final tightening to avoid deforming the straps or over-compressing isolators.
13. 13

    Reconnect fuel lines
    Reconnect the fuel supply and return lines to the fuel pump module on top of the tank. Push each quick-connect fitting straight onto its port until you hear or feel a distinct click, indicating the fitting is locked. Gently tug on each line to verify it is securely connected and will not pull off.
14. 14

    Reconnect electrical connector
    Reconnect the fuel pump module electrical connector, pressing firmly until the locking tab engages. Verify the connection is secure by gently pulling on the connector body.
15. 15

    Reconnect fuel filler hose and vent lines
    Slide the fuel filler hose back onto the tank inlet, ensuring it is fully seated. Install and tighten the hose clamp securely. Reconnect all vent lines to their respective ports on the tank, matching the routing noted during removal. Install and tighten clamps on vent lines.
16. 16

    Reinstall exhaust connection
    Reposition the rear exhaust section to align with the mid-pipe flange. Install new exhaust flange gasket if original is damaged. Install flange bolts and tighten in a cross pattern to ensure even loading. Tighten exhaust flange bolts to the factory-specified torque from the 2008 Viper 8.4L V10 service manual. Verify the spec before tightening rather than relying on an estimated value.
17. 17

    Remove jack and verify clearances
    Carefully lower and remove the transmission jack from under the fuel tank. Visually inspect that the tank is properly seated in the straps, all lines have adequate clearance from exhaust and suspension components, and nothing is pinched or kinked. Check that fuel filler hose has proper clearance and is not twisted.

Reassembly

1. Reinstall fuel pump relay in the power distribution center.
2. Reconnect negative battery cable to battery terminal.
3. Lower vehicle from jack stands.
4. Add fuel if tank was drained, adding at least 2-3 gallons to ensure fuel pump is submerged.

Verification

• Turn ignition key to ON position (without starting) for 5 seconds, then OFF. Repeat this cycle 3-4 times to allow fuel pump to prime the system and build pressure.
• Inspect all fuel line connections, filler hose, and vent lines for any signs of fuel leakage while system is pressurized.
• Start engine and allow to idle. Monitor for fuel leaks, unusual odors, or fuel pressure warning lights.
• Check underneath vehicle for any fuel drips or seepage at tank connections and along fuel lines.
• Verify exhaust system is not contacting fuel tank, straps, or lines. Listen for any rattles or contact sounds.
• Test drive vehicle and monitor for any fuel odors in cabin, fuel gauge operation, and check engine light. Re-inspect all connections after test drive.

More procedures for this vehicle