How to replace the gas tank on a subaru legacy

Written by kyle unser
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How to replace the gas tank on a subaru legacy
Pumped gas is directly funnelled into your gas tank. (petrol station image by Mat Hayward from

Over time, the gas tank in your Subaru Legacy can rust or corrode, requiring a replacement tank. The gas tank is incorporated within the exhaust system. The exhaust system is found under the rear of your Legacy, tucked between the rear wheels.

Skill level:

Things you need

  • Safety goggles
  • Car jack
  • Replacement gas tank
  • Metric ratchet set
  • Flathead screwdriver
  • Fuel siphon set
  • Jack stands

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  1. 1

    Park your Subaru Legacy on a flat surface. Lift the rear end of the vehicle in the air with your car jack and place the car on jack stands.

  2. 2

    Pop the bonnet and remove the black negative connector on the battery and close the bonnet.

  3. 3

    Put your safety goggles securely on to protect your eyes from fuel.

  4. 4

    Drain the remaining fuel in the defective gas tank. Use the fuel siphon set and place the hose in the tank from the gas cap, create suction with the vacuum pump from the set, and empty the tank into the drain pan.

  5. 5

    Remove the exhaust manifold assembly connecting to your gas tank. Use the metric ratchet set to detach the bolts. The exhaust manifold set includes the exhaust pipe, muffler, and attached fuel lines. Save the bolts for reassembly.

  6. 6

    Remove the fuel filler pipe attached at the fuel housing outlet of your Legacy. Use your metric ratchet set to unbolt the fuel filler pipe, and use the flathead screwdriver to remove the brackets hoisting the pipe. Place the bolts and screws aside in a separate pile for the replacement gas tank.

  7. 7

    Remove the defective gas tank. Use your metric ratchet set to remove the brackets by detaching the bolts holding the tank in place. Save the bolts.

  8. 8

    Mount the replacement gas tank. Bolt the new gas tank with the brackets and bolts from Step 6 with your metric ratchet set. Securely fasten the brackets into place.

  9. 9

    Attach the fuel filler pipe to your Legacy's fuel housing outlet. Use the bolts and screws from Step 5 to reassemble into place, fastening the bolts and screws with your metric ratchet set and flathead screwdriver.

  10. 10

    Bolt the exhaust manifold assembly onto the replacement gas tank. Use the metric ratchet set and the bolts from Step 4 to reattach the assembly. Check the fuel lines thoroughly for any leaks.

Tips and warnings

  • Having an associate or friend to aid with the removal of a gas tank can shorten the necessary time to complete the job.
  • Using a car lift, instead of a car jack, can greatly reduce the time it takes to replace your gas tank.
  • When replacing your gas tank, exercise extreme caution because gasoline is a highly flammable substance.
  • If your Legacy is an All-Wheel Drive (AWD) vehicle, your rear differential must be removed first before removing the gas tank.

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