Fuel Tank Strap

This procedure covers the removal and replacement of the fuel tank retaining straps on a 2007 Ram 3500 with the 5.9L Cummins diesel engine and 4WD configuration.

Warnings

Tools required

Parts

• Fuel tank strap kit (2 straps) × 1 — Use OEM specification - Mopar 52129803AB or equivalent
• Fuel tank strap hardware kit × 1 — Use OEM specification if existing hardware is corroded

Preparation

1. Park vehicle on level, solid ground and engage parking brake
2. Place wheel chocks behind front wheels
3. Allow fuel system and exhaust components to cool completely if vehicle was recently operated
4. Drain fuel tank to 1/4 full or less to reduce weight. Use approved fuel transfer pump and storage containers
5. Disconnect negative battery cable to eliminate ignition sources
6. Raise rear of vehicle using floor jack and support securely on jack stands rated for vehicle weight. Stands should be placed on frame rails
7. Remove driver side rear wheel for better access if working on driver side strap
8. Inspect work area underneath vehicle and identify fuel tank, straps, filler neck, and electrical connections

Procedure

1. 1

   Relieve fuel system pressure and disconnect filler neck
   Remove fuel cap to relieve any pressure in the tank. Locate the fuel filler neck connection where it enters the fuel tank (typically the driver side/rear of the tank on this vehicle). Loosen the hose clamp securing the filler neck to the tank using a flathead screwdriver or 8mm socket. Disconnect the filler neck from the tank and move it aside. You may need to gently twist and pull to break the seal. Some residual fuel may spill from the filler neck connection when disconnected. Position drain pan to catch any spillage.
   ⚠Fuel will drain from filler neck when disconnected. Position drain pan to catch spillage.
2. 2

   Disconnect fuel lines and electrical connections
   Locate the fuel supply and return lines on top of the fuel tank, along with the fuel pump electrical connector. Disconnect the fuel supply and return lines at the fuel tank sending unit/transfer pump module (verify fitting type — release quick-disconnect tabs or loosen line fittings as applicable for this diesel application). The electrical connector has a red safety lock - lift this lock and press the release tab to disconnect. Label connections if needed for reassembly. Cap or plug fuel lines to prevent contamination.
   ⚠Fuel will drain from disconnected lines. Keep drain pan positioned under work area.
3. 3

   Disconnect EVAP system lines
   Locate the evaporative emissions (EVAP) vent line and vapor line connections on the fuel tank. These are typically on the driver side of the tank. Disconnect these lines by pressing the release tabs on the quick-disconnect fittings. On this diesel model, disconnect any tank vent/vapor lines present (diesel applications typically use a vent line and rollover valve rather than a full gasoline EVAP system). Move lines out of the way to prevent damage during tank lowering.
4. 4

   Position transmission jack under fuel tank
   Place the transmission jack or fuel tank jack directly under the center of the fuel tank. Raise the jack until it just contacts the tank bottom with light pressure. The jack should support the tank weight but not lift it. Ensure the tank is balanced on the jack. Use a piece of wood between the jack and tank to distribute load and prevent tank damage. The tank must be securely supported before removing straps.
   ⚠️Tank must be properly supported before loosening strap bolts. Failure to support tank can result in crushing injury.
5. 5

   Apply penetrating oil to strap bolts
   Locate the fuel tank strap mounting bolts. On the 2007 Ram 3500, there are two straps supporting the tank. Verify strap mounting configuration on the vehicle — straps may be hinged at one end and bolted at the other (2 bolts total) or bolted at both ends (4 bolts total). The front bolts thread into frame mounts, and rear bolts secure the strap at the back of the tank. Spray all four bolts generously with penetrating oil and allow 10-15 minutes for penetration. These bolts are prone to corrosion.
6. 6

   Remove passenger side fuel tank strap
   Using the correct size socket (verify size on vehicle — commonly 15mm for these strap bolts), begin removing the passenger side strap bolts. Start with the rear bolt first, then move to the front bolt. Support the strap as you remove the final bolt to prevent it from falling. The strap is under tension and will release when the second bolt is removed. Lower the strap carefully and remove it from under the vehicle. If bolts are severely rusted, use a breaker bar or impact wrench.
   ⚠Strap is under tension. Control strap movement as final bolt is removed to prevent sudden release and injury.
7. 7

   Remove driver side fuel tank strap
   Repeat the removal process for the driver side strap. Remove the rear bolt first using an 18mm socket, then remove the front bolt. Support the strap and control its release. Once both bolts are removed, lower the strap and remove it from the vehicle. With both straps removed, the tank is now supported only by the transmission jack.
   ⚠Strap is under tension. Control strap movement as final bolt is removed.
8. 8

   Inspect mounting hardware and frame brackets
   With straps removed, inspect the frame-mounted brackets where strap bolts thread in. Check for rust, damage, or stripped threads. Inspect the strap mounting bolts for thread condition and corrosion. Clean mounting surfaces with a wire brush. If threads are damaged or brackets are severely corroded, they should be replaced before installing new straps. Also inspect the fuel tank shield (if equipped) for damage.
9. 9

   Position and install new driver side strap
   Take the new driver side fuel tank strap and position it around the tank and into the frame mounting brackets. Ensure the strap is oriented correctly with the mounting holes aligned. Thread in both mounting bolts by hand first to ensure proper thread engagement. The strap should sit flush against the tank bottom without twisting. Snug bolts finger-tight but do not fully tighten yet. New straps may have a protective coating.
10. 10

    Position and install new passenger side strap
    Install the passenger side strap using the same method. Position the strap around the tank and align with frame brackets. Thread both bolts by hand to check alignment. Leave bolts finger-tight. Verify both straps are positioned symmetrically and the tank is sitting level on the straps before final tightening.
11. 11

    Tighten fuel tank strap bolts
    Using an 18mm socket and torque wrench, tighten all four strap mounting bolts in a cross pattern (driver front, passenger rear, passenger front, driver rear). Factory torque specification should be verified against service documentation before final tightening. If unavailable, use approximately 30 ft-lbs as conservative guidance for this fastener size and confirm straps pull the tank up evenly. Ensure straps are pulling the tank up evenly against the body. After tightening, slowly lower the transmission jack to transfer tank weight to the straps. Verify tank is secure and not sagging.
    ℹ️Factory torque specifications not available. Use 30-35 ft-lbs as general guidance for this hardware size and application.
12. 12

    Reconnect EVAP system lines
    Reconnect the EVAP vent and vapor lines to their fittings on the fuel tank. Push each line firmly onto its quick-disconnect fitting until you hear or feel a click indicating the lock has engaged. Gently pull on each line to verify it is secure and will not disconnect.
13. 13

    Reconnect fuel lines and electrical connector
    Remove any plugs or caps from the fuel lines. Reconnect the fuel supply and return lines to the fuel pump module by pushing them firmly onto the quick-disconnect fittings until they click into place. Verify both connections by pulling gently on the lines. Reconnect the fuel pump electrical connector and engage the red safety lock to secure it.
14. 14

    Reconnect filler neck
    Guide the fuel filler neck back onto the tank inlet. Ensure the neck is fully seated on the tank fitting. Reinstall and tighten the hose clamp securely using a flathead screwdriver or 8mm socket. The clamp should be positioned over the ribbed section of the filler neck for proper sealing.
15. 15

    Final inspection and testing
    Perform a final visual inspection of all connections, straps, and hardware. Verify nothing is hanging loose or unsecured. Reconnect the negative battery cable. Reinstall the rear wheel if removed and torque lug nuts to specification. Lower the vehicle from jack stands. Add fuel if tank was significantly drained. Cycle the ignition to ON (without starting) several times to allow the electric lift pump to prime the fuel system; if the fuel system was opened and air introduced, follow the Cummins diesel fuel system priming/bleeding procedure before starting. Start engine and check for fuel leaks at all connection points. Monitor fuel pump operation for unusual noises.
    ⚠️Check thoroughly for fuel leaks before declaring job complete. Even small leaks present fire hazard.

Reassembly

1. Torque fuel tank strap bolts in cross pattern to ensure even loading
2. Verify all fuel line quick-disconnect fittings are fully engaged and locked
3. Ensure EVAP lines are properly routed and not kinked or pinched
4. Check that filler neck hose clamp is tight and positioned correctly
5. Confirm fuel pump electrical connector is fully seated with safety lock engaged

Verification

• Visually inspect fuel tank to confirm it is sitting flush against vehicle body without sagging or misalignment
• Check all fuel line connections for leaks with engine running - look for wet spots or fuel odor
• Verify fuel gauge reads correctly and fuel pump operates normally without unusual noise
• Inspect underneath vehicle for any loose hardware, disconnected lines, or tools left behind
• Test drive vehicle and monitor for fuel odors, gauge anomalies, or check engine lights related to fuel system
• Re-inspect strap bolts after 50-100 miles of driving to ensure they have not loosened

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