VRaptor SpeedWorks "You Dream It, We Build It!"

Fuel Tank Cross-Over Kit ’04 Tanks

December 24, 2015  by Shane

This kit contains all of the same parts as the Fuel Tank Cross-Over kit with the exception of the aluminum plate that takes the place of the fuel sender/jet pump assembly on the standard kit.  This plate is not needed on the ’04 tanks since the pumps and senders are all mounted in thru the top of the tank instead of at the bottom of the tank.  Worrying about fuel leaks with this system is a thing of the past.  The pressure sealing washers provided in this kit provide a leak-proof seal between the AN fitting and the surface of the tank.  Included with this kit are:

2 – Pressure sealing washers to seal the AN fitting to the outside surface of the tank.

2 – Square-cut O-rings to place inside the tank on the AN fittings.

2 – Aluminum washers to place inside the tank under the nut to support the square-cut O-rings.

Please note that the aluminum plate in the bottom photo is not included in this kit.  This photo is provided only to show the assembly of the square-cut O-ring and aluminum washer on the inside of the tank.

For installation, you will need to trim the “webbing” out of the ID of the pressure sealing washers (these are the washers you see in the photo that are inside the plastic packaging that are moulded to the steel outer washer).  You can do this with a razor blade or exacto knife……just be sure to not cut into the main part of the rubber seal.  Install the pressure sealing washer onto the AN fitting.  Install the AN fitting with the pressure sealing washer thru the hole in the plastic tank.  On the inside of the tank install the square cut rubber O-ring, then the aluminum washer and then the nut.  DO NOT OVER-TIGHTEN THE NUT!!  100% of the seal takes place with the pressure sealing washer between the hex flange of the AN fitting and the plastic tank.  The square cut O-ring inside the tank DOES NOT MAKE A SEAL.  The O-ring is there only to provide a consistent pressure to the outside pressure sealing washer and make up for variations in tank wall thickness at the drilled hole location in the tank.  The nut that secures the AN fitting only needs to be tightened enough to pinch the pressure sealing washer against the tank enough to make contact all the way around and seal.  If you over-tighten the nut, it will squish the O-ring out from behind the aluminum washer, tear it in half and then you will no longer have any tension against the pressure sealing washer.  If you look at the 3rd photo down, you can see a good example of a proper installation.  The outer edge of the O-ring is crowned out to be about right at the OD of the aluminum washer.  This amount of tension will provide constant contact for the pressure sealing washer.  Do NOT tighten the nut by holding the nut stationary and turning the AN fitting with a wrench.  This will tear/roll the pressure sealing washer.  Once you reach the proper tension, you will notice that there is still “compliance” in the fitting…..in other words, with the crossover 90 degree fitting installed (be sure to hold the AN fitting in the tank stationary while you tighten the crossover AN hose end) you will be able to rock the fitting around in the tank slightly if you pull or push on the fitting with some force.  This is normal!  As long as the pressure sealing washer is pinched tightly between the AN hex flange and the aluminum plate or tank, it will not leak.