S B 10-1009 55 Gallon Replacement Fuel Tank Installation Guide

INSTALL INSTRUCTIONS FOR 1O-1OO9

BEFORE YOU START

• Please read the entire product guide before proceeding
• Ensure all parts are present.
• If you are missing any parts, please call or text us at (909)-675-1313
• Do not work on your vehicle while the underbody components are hot.
• Make sure the vehicle is in park or the parking brake is set if you plan on working on the ground. If working on a lift, make sure the vehicle is lifted safely and securely.
• Drain your original fuel tank before beginning the S&B Installation process. S&B Tanks recommends removing only an empty or near empty tank for your safety. We recommend using a siphon or electronic transfer pump.
  – Disconnect and isolate both of the negative battery cables
  – Before installing S&B Tank, conduct pressure test to ensure o’ring is properly seated.
  – In-bed Auxiliary Fuel Tanks will void the Lifetime Warranty.
  – Nozzle at high flow fuel station may continue to “click off”. Tank is designed to work at regular fuel stations.

REQUIRED TOOLS

• Flathead Screwdriver or 5/16″ Nut Driver
• Torx 30
• Mallet/Hammer
• 13mm Socket
• 19mm Deep Socket
• 10mm Socket
• Ratchet
• 12″ Driver Extension

ITEM
NO.| PART
NUMBER| DESCRIPTION| QTY.
---|---|---|---
1| 10-1009| HIGH CAPACITY REPLACEMENT FUEL TANK| 1
2| 111053-00| REAR CROSS MEMBER STRAP FOR 10-1021| 1
3| 1I105401| FRONT STRAP FOR 10-1021| 1
4| 1I1083-00| RETAINING/LOCKING RING| 1
5| TI1094C-00| 0-RING, 8mm CS, NBR, 50 DURO| 1
6| TI1114-00| U-Bolt For 10-1009| 1
7| TI1116-00| Front Hook for 10-1009, 2005-2012| 1
8| 711116-00| Front Hook for 10-1009 ,2013+| 1
9| T11123-00| NYLON-INSERT LOCK NUT| 2
10| 1I1124-00| WASHER| 2
11| TI 1129-00| 90° BRASS ELBOW, 1 /2NPT TO 3/4″ BARB| 1
12| TI1141-00| VENT-BREATHER| 2
13| TI1149-15| Fuel Hose, 5/16″ x 15″, BK| 1
14| 1I1149-50| Fuel Hose, 5/16″ x 50″, BK| 1
15| T11170-32| Fuel Hose, 3/4″ x 32″, BK| 1
16| TIM 75-00| ICV, IN FILL PIPE| 1
17| 1I1226-00| OE STYLE ROLLOVER VENT VALVE| 2

STEP 1
Remove the hose clamps from the filler neck and the fill vent.
5/16 socket or flathead screwdriver.

STEP 2
Remove the blue safety clip on the fuel line then depressed the tab to remove.
IF you have a 3rd gen mega cab, both fuel lines will be disconnected at the sending unit

STEP 3
With the jack underneath the tank, remove the bolts securing the front and near strap.

STEP 3 (IMAGE 2)

STEP 4
Once the bolts are out, remove the front and rear straps.

STEP 5
Drop the tank 2-3 inches and if you have any remaining lines on top of the sending unit, make sure you disconnect those.

STEP 6
Drop the tank fully out of the vehicle and begin getting the locking ring removed.

STEP 7
Once the locking ring is off, begin transferring the sending unit over to the S&B tank. We will provide you with a new O-ring that must be used. When installing the sending unit, make sure to point the tab towards the arrow on the tank. There will be two  different arrows on the tank, make sure you line up the correct one according to the year of your truck.

STEP 8
This S&B tank will also include a new locking ring that must be applied and used. Slide the locking ring over the sending unit then twist into position.

STEP 88
Once the locking ring is on and lined up, use the locking ring removal tool (as shown) or a mallet to get everything popped into place.

STEP 9
Transfer over the hose clamps and filler neck tube.

STEP 10
Once the filler neck is off the stock tank, press the check valve in (make sure the “FLOW” arrow is pointing towards the tank)
Then install the filler neck onto the S&B tank and tighten down the hose clamp.

STEP 10 (IMAGE 2)

STEP 11
Remove the hose clamp on the factory fill vent.

STEP 12
We will provide a new fill vent for the S&B tank, take fill vent off the S&B tank and reinstall it on the truck.

STEP 12B
Push the new fill line and hose clamp onto the filler neck vent. Tighten down once it is fully on the filler neck vent.

STEP 13
Install the U-Bolt for the front mounting support. To install, slide it up and over the frame rail and make sure there is plenty of room around the fuel and brake lines.

STEP 14
Begin raising the fuel tank up and make sure the filler neck goes over the rear crossmember, as well as the rear rollover vent line that comes from the fuel tank.

STEP 15
Reconnect the electrical and fuel lines.

STEP 16
Trim the fill level vent line.
Make sure to cut it short enough so there is no dips in the hose.

STEP 16B
Once its cut, slide the hose clamp onto the line then reconnect it to the barb on the S&B tank.

STEP 17
Reinstall the longer strap by clipping the frame side into place and installing the driveline side with the nut. Once the nut is in place and connected with the mounting stud, tighten down.

STEP 18
Line up the front hook support with the U-Bolt then install both the washer and nuts. Then tighten

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STEP 20
Make sure the hose clamp on the filler neck is fully tightened down and be sure both rollover vent valves are pulled out and showing as seen in the image. Then zip tie both valves to the filler neck and filler vent.

FINAL CHECKLIST

This final checklist is very important.

1. Make sure all bolts and nuts are safely fastened and torqued.
2. Ensure there is proper driveshaft clearance.
3. Double check fuel line connections, the electrical connection as well as the vent and fill lines.
4. Lastly, fill the tank full and check for any leaks.

If you have any questions,
call or text us at
909.675.1313
https://sbfilters.com/pages/10-1009install

References

• 10-1009install – S&B

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