Complete removal and replacement of the fuel tank assembly on a 2014 Ram 2500 with 6.7L Cummins diesel engine, including disconnection of fuel lines, electrical connections, and filler neck.

Warnings

Tools required

Parts

• Fuel tank (if replacing) × 1 — Use OEM specification
• Fuel tank strap set × 1 — Use OEM specification
• Fuel line O-ring kit × 1 — Use OEM specification
• Filler neck seal/grommet × 1 — Use OEM specification
• Tank shield hardware (if corroded) × 1 — Use OEM specification

Preparation

1. Park vehicle on level, solid ground in well-ventilated area away from ignition sources
2. Place wheel chocks at front wheels
3. Ensure fuel tank is as empty as possible (run tank to reserve or drain fuel into approved container)
4. Disconnect negative battery cable and secure away from terminal
5. Allow exhaust system to cool completely if vehicle was recently running (minimum 1 hour)
6. Raise vehicle using floor jack and support securely on jack stands at frame rails behind cab
7. Ensure vehicle is stable and will not shift during work
8. Position transmission jack or fuel tank support stand nearby and verify it can reach tank location

Procedure

1. 1

   Relieve fuel system pressure
   Locate the fuel pump relay in the Power Distribution Center (PDC) under the hood. Remove the fuel pump relay. Attempt to start the engine (it will not start or run briefly then stall). Crank engine for 5 seconds to purge remaining pressure. Turn ignition off. This relieves residual pressure in fuel lines.
   ⚠Even after pressure relief, some fuel will remain in lines and will spill when disconnected.
2. 2

   Remove fuel tank shield and heat shields
   From under vehicle, locate the plastic fuel tank shield covering the front and sides of the tank. Remove shield mounting screws and carefully lower shield away from tank. If present, remove any heat shields between exhaust and tank by removing mounting hardware. Inspect shields for damage and set aside for reinstallation.
   Torque spec

   Cover Screws15 Nm (11 lb-ft)
3. 3

   Disconnect fuel filler neck
   Locate the fuel filler neck connection at the tank (driver side rear). Loosen the filler neck hose clamp using appropriate tool. Carefully twist and pull the filler neck hose off the tank inlet. Diesel fuel will drain from neck; position drain pan underneath. Disconnect the vent line from the tank using quick-disconnect tool if equipped, or loosen clamp and remove hose.
   ⚠Fuel will spill from filler neck. Have drain pan and absorbent materials ready.
   Torque spec

   Filler Neck Clamp4 Nm (3 lb-ft)
4. 4

   Disconnect electrical connections
   Locate electrical connectors on top of fuel tank for fuel pump module, fuel level sender, and any fuel heater connections. Press connector locking tabs and carefully disconnect each connector. For connectors with secondary locks, slide lock away before pressing release tab. Let connectors hang safely away from tank or secure to frame with mechanics wire.
   ℹ️Take photos of connector orientations for easier reassembly.
5. 5

   Disconnect fuel supply and return lines
   Using appropriate quick-disconnect fuel line tools, disconnect the main fuel supply line (high pressure) and return line from the tank. These are typically located on the passenger side of the tank. Push the tool onto the line, then push inward on the tool while pulling the line away. Some residual diesel fuel will drain; catch in drain pan. Cap or plug disconnected lines to prevent contamination.
   ⚠️Fuel will spray when lines are disconnected. Wear safety glasses and have drain pan positioned.
   Torque spec

   Fuel Line Fittings25 Nm (18 lb-ft)
6. 6

   Position tank support
   Position transmission jack or tank support stand directly under center of fuel tank. Raise support until it makes light contact with tank bottom. Secure tank to support using ratchet straps or chains to prevent tank from shifting or falling during removal. Verify support is stable and centered.
   ⚠️Tank must be securely supported before loosening straps. Unsupported tank can fall causing severe injury.
7. 7

   Remove tank strap bolts
   Locate the two fuel tank strap mounting bolts at the rear of each strap (typically 4 bolts total). Apply penetrating oil if threads are corroded. Using appropriate socket, remove all tank strap mounting bolts. Keep track of any washers or spacers. Once bolts are removed, carefully pivot straps downward and away from tank while supporting tank weight with jack.
   ⚠️Tank weight shifts to jack as straps are loosened. Ensure jack is secure and stable.
   Torque spec

   Tank Strap Bolts35 Nm (26 lb-ft)
8. 8

   Lower and remove fuel tank
   Verify all lines, hoses, and electrical connections are disconnected from tank. Slowly lower the transmission jack while guiding the tank down. Watch for any forgotten connections or obstructions. Tank may need to be angled or rotated slightly to clear frame rails and exhaust components. Once clear of vehicle, lower completely and roll tank assembly away from under vehicle.
   ⚠️Tank is heavy and awkward. Use assistant to guide tank and prevent it from tipping off jack.
   ⚠Remaining fuel in tank will slosh and shift center of gravity. Move slowly and maintain control.
9. 9

   Inspect and prepare tank area
   With tank removed, inspect frame rails, tank straps, and mounting points for corrosion or damage. Clean mounting surfaces with wire brush. If reusing tank, drain completely and inspect for damage, corrosion, or contamination. Inspect tank straps for cracks or severe corrosion and replace if necessary. If installing new tank, transfer fuel pump module and sender as needed (separate procedure).
   ℹ️This is ideal time to replace fuel pump module or filter if needed.
10. 10

    Install new O-rings on fuel line fittings
    Inspect all fuel line quick-connect fittings and O-rings. Replace all O-rings with new ones from O-ring kit, even if old ones appear serviceable. Lightly lubricate new O-rings with clean diesel fuel. Inspect quick-connect clips for damage and replace if bent or broken.
    ⚠Old or damaged O-rings will cause fuel leaks. Always use new O-rings during fuel tank installation.
    Torque spec

    Fuel Line Fittings25 Nm (18 lb-ft)
11. 11

    Raise tank into position
    Position fuel tank on transmission jack with straps if reusing, or secure with chains. Ensure tank is centered and stable on jack. Carefully raise tank toward vehicle frame, angling as necessary to clear exhaust and frame components. Align tank into mounting position, ensuring all mounting points line up with frame. Raise until tank is at proper height for strap installation.
    ⚠️Control tank carefully while raising. Do not place body parts between tank and frame.
12. 12

    Install tank straps and secure tank
    Pivot tank straps up and around tank. Align strap bolt holes with frame mounting points. Install tank strap bolts with any washers or spacers in original positions. Hand-tighten all bolts first, then torque in cross pattern (alternate sides) to specified torque. Verify tank is sitting properly in straps and is not twisted or misaligned.
    Torque spec

    Tank Strap Bolts35 Nm (26 lb-ft)
13. 13

    Reconnect fuel lines
    Reconnect fuel supply and return lines to tank fittings. Push each line onto fitting until you hear/feel a distinct click indicating the connection is locked. Gently pull on each line to verify it is secure and will not separate. Verify O-rings are properly seated by checking for gaps between fitting and line.
    ⚠️Improperly connected fuel lines will leak under pressure causing fire hazard. Verify each connection is fully locked.
    Torque spec

    Fuel Line Fittings25 Nm (18 lb-ft)
14. 14

    Reconnect electrical connections
    Reconnect all electrical connectors to fuel pump module, level sender, and fuel heater. Ensure each connector locks fully with audible click. Engage any secondary locking mechanisms. Verify connectors are oriented correctly and pins are not bent.
    ℹ️Refer to photos taken during disassembly to verify correct connections.
15. 15

    Reconnect filler neck and vent
    Push fuel filler neck hose fully onto tank inlet. Install and tighten filler neck clamp to specified torque. Reconnect vent line to tank, ensuring quick-disconnect is fully seated or hose clamp is tightened. Verify filler neck is not kinked or strained.
    Torque spec

    Filler Neck Clamp4 Nm (3 lb-ft)
16. 16

    Reinstall heat shields and tank shield
    Reinstall any heat shields between exhaust and tank using original mounting hardware. Position fuel tank shield over tank and secure with mounting screws torqued to specification. Ensure shield is properly seated and not contacting tank or interfering with any lines or hoses.
    Torque spec

    Cover Screws15 Nm (11 lb-ft)

Reassembly

1. Reinstall fuel pump relay in PDC
2. Reconnect negative battery cable to battery terminal
3. Lower vehicle from jack stands carefully and remove stands
4. Add minimum 5 gallons of diesel fuel to tank to ensure adequate fuel for system priming
5. Do not start engine yet - proceed to verification steps

Verification

• Turn ignition to ON position (do not start) for 10 seconds, then OFF. Repeat 3-4 times to prime fuel system and build pressure
• Inspect all fuel line connections, filler neck, and tank straps for any fuel leaks while priming
• Have assistant turn ignition to ON while you inspect underneath for leaks with flashlight
• Start engine and let idle. Engine may take longer than normal to start on first attempt while system primes
• With engine running, inspect entire fuel system from tank to engine bay for any leaks or drips
• Check for proper fuel gauge operation on instrument cluster
• Rev engine to 1500 RPM and hold for 30 seconds while watching for leaks under increased pressure
• Turn engine off and recheck all connections after 5 minutes for delayed seepage
• If any leaks are found, relieve fuel pressure, repair leak source, and repeat verification
• Test drive vehicle and monitor for fuel odors, gauge operation, and engine performance issues
• After test drive, perform final inspection of all connections for leaks or loose components

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