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Technical / Installation Articles - Body Interior / Exterior


2004 Jeep Wrangler X Warn Fuel Tank Skid Plate Ins

Article written by FrozenW

Date Added: 05/07/2006

The Warn skid plate is made of 3/16” thick steel and gives you an extra inch of clearance to the rear of the Jeep for rough terrain.

The real nice thing about this skid plate is IT BOLTS TO FACTORY ATTACHMENT POINTS (same holes that the OEM skid plate does).

Kit includes:
  • 1 Gas Tank Skid Plate
  • 2 Wire Ties (Zip Ties)
 

Installation

1. Remove the eight screws from the filler neck and the vent line. The first picture shows the filler neck completely removed from the gas tank, making it easier to drop the tank.

2. The lines and wiring harness you will be disconnecting.

3. To disconnect the wire harness, you must slide over the red plastic piece. To do this you must first slide up the small red tab in the drawing (just the small inside piece), and then slide over the tab. Next, disconnect the wiring harness.

4. To disconnect the fuel lines in a 2004 Jeep X, you must use needle nose pliers or two small picks to spread the horseshoe clip and push it out of the fitting. Do not pry out the clip because it is made of plastic and will snap.
 Disconnecting the high-pressure fuel line will spray some gas, so wrap a rag around the connection as you pull it apart. Be careful not to damage the O-ring inside the fuel fitting. -- Be very careful with the vapor lines. If you kink or bend these lines it will set a Diagnostic Trouble Code (DTC). That results in a trip to the dealer to find out what line is leaking.

5. The check value lines need to be disconnected in the same way as the fuel line (see items 8 and 11).

6. After you disconnect these lines you will need to remove the five fuel line brackets from the tank. See the pictures below to see the brackets and where they are located.

7. Fitting from the gas tank.

8. Position a floor jack (I used two floor jacks) under the OEM skid plate and remove the bolts. Slowly lower the skid plate until you can disconnect the entire fuel line brackets, fuel line, and check value lines. Once you get the tank out, just remove the straps to the OEM skidpan and remove the tank.

9. In the pictures to the side you can see the difference in sizes.

10.  One-inch difference

11.  To install the new Warn skid plate just do everything in reverse.

Final Thoughts

Well that is it! Overall, it’s not a hard install. Just remember to take your time and not rush.


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