Here's a pic of a Kilby skidplate all shiny and new.
Remove the fuel pump relay from your Power Distribution Center (PDC)
Disconnect the negative battery cable.
Remove the gas cap and bezel holding it to the tub.
Cut this zip-tie holding the axle vent tube to the filler hose.
Here is a pic of the electrical connector as well as the EVAP and high pressure line just below it.
Using a floor jack and some help, unbolt and lower your gas tank.
Remove the gas tank straps using a 1/2" socket
Place your gas tank into your new skidplate and strap it in.
Place everything back onto your floor jack and raise it into place.
Kilby Jeep Gastank Skidplate

When you think of the word beefy, a Kilby Gastank Skidplate should come to mind because this thing is it! If you are like me, you've wheeled your Jeep over one too many obstacles that you probably shouldn't have and smacked the crap out of the piece of tin-foil holding your tank.... Not good! Well, the Kilby skid is the solution and should be one of the first mods you do to your rig. No point having an awesome lift and big tires if you're stranded on a trail with a ruptured gas tank. Above and beyond the great protection this skid offers (believe me, I've tested it too), the design of it will also give you a bonus 1" of ground clearance too! This skid can be purchased directly from Kilby Enterprises, costs only $225 and is easy to install. This is a must have for your Jeep.

What You Will Need
• Deep well and short 1/2" sockets
• 12" long Ratchet Extension
• Ratchet
• Phillips and Flathead screwdrivers
• Floor Jack
• Hammer
• Shop rags
• Wire Cutters
• A Friend

1. Drive your Jeep around until you have virtually no gas left in the tank. Every gallon left in is a significant amount of sloshing weight you don't want to deal with.

2. Park your Jeep on a level surface.

3. You will need to release the pressure in your fuel system. To do this, remove your fuel cap and then pull your fuel pump relay from the PDC as shown in the pic to the left. Start and run your engine until it stalls. Attempt to restart your engine until it will no longer run. Turn off your ignition and then disconnect the negative battery cable.

4. Remove your gas cap and the bezel attaching it to the tub. There are 8 screws holding this in place.

5. Put the gas cap back on to keep crap out of the tank.

6. Push the filler hose out of the way the best you can, locate and then cut the zip-tie holding the axle vent tube to the filler hose.

7. The directions that came with my skid notes the removal of "the ground strap attached to the top of the drivers side shock mount. You can access this between the frame and the body." My 2000 TJ did not have any such strap and so I ignored this step.

8. Climb underneath your Jeep on the driverside and then locate the electrical connector at the front left corner of the gas tank (see pic on the left). Now disconnect it by sliding the red clip to the side then separate the two connectors.

9. Just below the electrical connector is the EVAP hose. Disconnect it by twisting and pulling carefully on it. Pay special care not to bend the steel tube.

10. The next step requires you to disconnect the high pressure line. Make sure you are not directly under the connection when you disconnect this line.

11. Using your fingers and pinching the two plastic tabs together, disconnect the high pressure line by separating the connection. The plastic tabs can be easily damaged or broken so no matter how much of a pain it is to do, DO NOT tools to do this part of the job.

12. Now, slide your floor jack under the center of your factory skidplate and crank it up until it touches the surface of the skid but not lift your Jeep up into the air. This is done to support the weight of the tank.

13. Remove the 3 nuts attaching the factory skidplate underneath your tub and then the 4 rear nuts that holding it to the rear cross member. Do not remove the 2 strap nuts at this time.

14. With the help of a friend, slowly lower your tank assembly while guiding the filler hoses around the frame. (NOTE: On 1997 model TJ's there should be a ground strap that is attached to the driverside frame rail which will need to be disconnected at this time.)

15. Before you start swapping everything out, do yourself a favor and do a trial fit first. With your new Kilby skidplate empty, lift it up into into place and check the fit. Some TJ owners may have to bend the front stand-alone mount toward the rear of the Jeep to allow the stud to line up correctly. If an adjustment is necessary, use a hammer to slightly bend the mount approx. 1/4"-1/2". Be sure to do another test fit.

16. Remove the 2 nuts holding the tank straps in place using a 1/2" socket. Make a note of the placement of the fuel lines and disconnect the drivers side vent hose that is connected to the roll-over valve. Now, lift up the two straps being careful not to bend them and then pull the gas tank out of the factory skid plate.

17. Slip the two straps into the Kilby skid holding them straight up and then place the gas tank into the skid. Insert the strap studs into the holes and then tighten the nuts. Make sure you DO NOT over tighten these nuts! Due to the new shape of your skid plate, you will not have to thread the nuts as far up the stud as the factory skid setup was. Only tighten them just enough to secure the tank and to keep it from moving. Re-attach the vent hose for the roll-over valve.

18. Raise the Kilby skid with gas tank in it into your Jeep while guiding the filler hoses between the frame and body. When you get close to the top, tilt the skid backward to allow the front mount to clear the track bar and then lift it a bit higher. Once the front mount is clear, reposition the skid and continue to lift. Be careful that you don't pinch the 2 hoses or connector while lifting it.

19. Loosely thread on the 7 skid plate nuts and then slide the Kilby skid as far back as you'd like. You will need to torque the 7 nuts to 141 inch lbs.

20. Remove your floor jack. Re-connect the high pressure hose by sliding the 2 fittings together until a click is heard. Then, re-connect the EVAP hose and electrical connector. Make sure you slide the red clip into place.

21. Zip tie your axle vent hose back on to the filler hose.

22. Reinstall the fuel filler bezel and then reconnect your batteries negative lead.

23. Start up your engine and check for any fuel leaks.

That should be it! Please let me know if you have any questions.
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