Jeep Cherokee XJ Fuel Pump Retaining Ring removal tool

Like so many other XJ owners on the internet I too encountered a completely stuck fuel pump retaining ring. After attempting to remove it using the ‘hammer and scredriver' method and only marring the cap I went looking for other solutions. The ‘universal’ tools on Amazon have very poor reviews but I found an incompatible tool from a Volvo forum that inspired me to make my own too.

Print Instructions

To allow for extra strength I printed with top, bottom, and wall thickness all set to 4. I used 15% infill and, full disclosure, this was not enough and the ratchet broke the square hole. I was able to use the circular holes to force it open by hand. After the initial breakage I reinforced it with a layer of duct tape. The final result was not pretty but it got the job done without needing to reprint. I would recommend 100% infill for anyone using this in the future.

Instructions for use

Remove the fuel tank from the vehicle
Route fuel pump wires through portal in top of tool (or wind inside of tool)
Align teeth on the cap and this tool
Insert a ½ drive socket into the center square and turn! (righty-tighty lefty-loosy)
In case of failure, use holes to force open by hand (or use the the holes and another tool for leverage!)

NOTE: When putting the retaining ring back on the fuel tank clean the threads thoroughly and add a petrol safe lubricant such as vasoline on the threads (mine was nearly as difficult to put back on as it was to take off without a lubricant).

Good luck!