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Unread 08-04-2008, 05:29 AM   #1
bearhunter
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1992 YJ Wrangler 
 
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Jeep gas tank modification

This spring I replaced the sending unit in my 15 gallon gas tank with one I got from Ebay. It worked fine but when full would not read full. This was OK with me as long as I knew when my tank was empty. Recently I read on on this forum that the only difference in the 15 gallon tank and 20 gallon tank was a 10 " tube that went into the vent tube of the tank and that if this tube was shortened to 2.5" then I would have a 20 gallon tank. So I decided to try it and see what happened. It was an easy modification. I was able to get to the tube by just removing the tire and the plastic cover. Remove the small hose that connects to the gas tank and push it out of the way. Look close and you will see a smaller diameter tube inside the tank The hardest part was removing this 10 inch tube. It was tight but I was able to get a hold of it with needle nose vise grips after using a screwdriver to wedge between the inner and outer tube. Using another larger pair of vice grips on the smaller needle nose vise grips, I was able to pry the 10 " inner hose out. I then cut this hose down to 2.5 " and reinserted this short piece back into the tank, using a plastic hammer to pound it back in. Then replace the small hose and tighten the clamp. Replace the plastic cover and tire. And your done. I then drove down to the gas station and filled up. Now my gas gage reads full and I have a 20 gallon capacity tank.

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Unread 08-04-2008, 05:36 AM   #2
AtzMaBoy
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This sounds like a great mod, are there any dangers in doing it? Has anyone had associated problems "in the long run"?
I ask because the tank is being dropped tonight for an unrelated fix and the timing couldn't be better if I were going to do the 15 to 20 mod.
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Unread 08-04-2008, 05:42 AM   #3
93jeepREDSOX
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No real problems in the long run, the only thing is your guage will read over full for the extra gas then when it gets to 15 it will read the same.
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Unread 08-04-2008, 05:46 AM   #4
AtzMaBoy
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Thanks! Now if we can only get a mod to allows us to pump 20 and only get charged for 15. (I think the used market on 15 gal poly tanks would skyrocket!)
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Unread 08-04-2008, 06:14 PM   #5
bearhunter
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Quote:
Originally Posted by AtzMaBoy View Post
This sounds like a great mod, are there any dangers in doing it? Has anyone had associated problems "in the long run"?
I ask because the tank is being dropped tonight for an unrelated fix and the timing couldn't be better if I were going to do the 15 to 20 mod.
No, dangers at all. This is what the factory did if you bought a Jeep with the 20 gallon tank. The only problem is since you have a fuel sender for a 15 gallon tank your fuel gage will read full for a longer time until the extra gas is used up. Since I must have put in a 20 gallon sending unit when I replaced mine, it reads correct for me now. Since you are removing you tank, this should be even easier to do.
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Unread 08-12-2008, 08:32 PM   #6
Bondo007
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real easy mod. Did it in about 35 min. this weekend. This way has to be easier than removing the plate and filler cover on the back. Thx for the post
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Unread 08-12-2008, 08:41 PM   #7
mtn_wrangler
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Quote:
Originally Posted by AtzMaBoy View Post
Thanks! Now if we can only get a mod to allows us to pump 20 and only get charged for 15. (I think the used market on 15 gal poly tanks would skyrocket!)
i believe the tank mod is only able to be done on the 90 or 91 and up yj's. i was thinking about doing this a while ago but that is what i was told
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Unread 08-12-2008, 08:54 PM   #8
Mean Max
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Correct, the '91 and newer models.
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Unread 08-13-2008, 04:37 PM   #9
mudbugII
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it is just as ez as he said.

I too did the mod this weekend. No problems at all, my vent tube actually came out really really easy. As an added bonus, for whatever reason, I can now pump fuel alot faster and keep it "latched" instead of holding the thing at weird angles in order to get gas in it.
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