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Unread 10-31-2004, 09:36 AM   #1
sjlplat
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YJ 15 to 20 gallon tank conversion

Common modification for '91 to '95 YJ's. Chrysler used the same tank in all of them to cut costs, and installed a longer tube in the filler to displace 5 gallons if you didn't purchase the 20-gallon tank option Here's a pretty good writeup:

http://www.4x4wire.com/jeep/tech/fuel/15to20gal/

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Unread 10-31-2004, 11:48 AM   #2
2muchfun
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The only thing I will add to that write up is:

1. If you just remove the license plate, there are access holes to the screws to remove the whole assembly without fighting the spring load like a mouse trap.

2. That Tube is NOT easy to get out of the hose, be patient and try not to damage the hose.
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Unread 11-03-2004, 12:53 PM   #3
mYJ
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That tube IS a PITA to remove... prepare for some scratched hands. Once I finally got it out I didn't cut it and return it, just threw it out. No problems four months later and the 33% increase in range is great!
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Unread 12-31-2004, 10:06 AM   #4
neZZr
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Anyone know if any of this is true for the TJ as well?

My '05 Rubi could seriously use some more range, but I don't much care to strap a gerry can on the back

*EDIT*
Just looked in DCX, found I already have a 19 gallon tank! (Code NF1S 19 GALLON W/TETHERED CAP FUEL TANK)

No wonder you guys with the 15gal tank need the mod!!
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Unread 12-31-2004, 02:46 PM   #5
BigWaylon
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Quote:
Originally Posted by neZZr
Anyone know if any of this is true for the TJ as well?

My '05 Rubi could seriously use some more range, but I don't much care to strap a gerry can on the back

*EDIT*
Just looked in DCX, found I already have a 19 gallon tank! (Code NF1S 19 GALLON W/TETHERED CAP FUEL TANK)

No wonder you guys with the 15gal tank need the mod!!
it can be done on a TJ, but in a different way...

'99 or '00 was the last year of the 15-gallon, though...

I did the mod on my '99, and it holds more fuel than the 19-gallon that came in my '01...

Greg
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Unread 01-01-2005, 11:00 AM   #6
US1
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Being a Jeep owner now for 2 months, I just read and did this modification just yesterday. Took me about 1 hr max. I just left the tube out completely. I just worked from underneath, w/o removing the license plate and filler neck. Didn't see the advantage of removing those parts. Can not believe the difference it made. Just got back from a 140 mile road trip and the gauge 'just' started to finally move.

Thanks for the tip.

'93 w/2.5L
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Unread 01-05-2005, 10:10 AM   #7
Micah
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anybody know of a write up on how to do this to a tj?
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Unread 01-05-2005, 09:58 PM   #8
BigWaylon
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Quote:
Originally Posted by Micah
anybody know of a write up on how to do this to a tj?
you ought to be able to find what you need in one of these...

any other questions, just shoot me a PM...

http://www.jeepforum.com/forum/f9/15-gallon-tank-vs-19-gallon-tank-83219/

http://www.jeepforum.com/forum/f9/15-19-gastank-conversion-84261/

this link is buried in there, and is a decent how-to with pics:

http://www.gottrail.com/TJ/TJfueltankconversion.html


...I would just advise not to follow his exact instructions, as he cut off both tubes inside the tank...all you need to do is cut the smaller diameter one...the other has a "ping-pong" ball in the end that you can feel, and is the anti-siphon valve...

Greg
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Unread 11-23-2005, 12:17 AM   #9
irdaniel
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15-20

I did this mod, and ran out of gas while pulling into the pumps...it took 20.6 gallons of gasoline....wow. True Story!
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Unread 11-23-2005, 10:45 AM   #10
theviper90210
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is it better to just remove the tube or take it out and cut it like in the write up, what do yall sugest and also how does it affect your gas guage? Thanks
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Unread 11-23-2005, 03:09 PM   #11
saminwy
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i just left the tube out. as far as the gas guage, it will just stay pegged at full for longer. then will read the same as it would have as a 15 gallon tank(ie: 1/2 tank would be 7.5 gallons, not 10)
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Unread 12-05-2005, 07:00 PM   #12
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Hey I just did this mod last night. The vent tube was a real pain to get out, like you said. I sprayed some Pam on it(with my finger jammed in the hole) after it had come out a little. I'm not sure if it helped though. Now I'm waiting for the loan to come through so I can fill the tank.
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Unread 08-02-2007, 01:52 AM   #13
BitterOso
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i did this mod today, and ended up with a nasty cut (all the way to bone) on my wrist when my pliers slipped off the vent tube. my wrist hit the edge of the cut-out for the gas tank access. anyone who is planning this mod, might want to tape some padding along that edge.
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Unread 10-15-2011, 05:15 PM   #14
AZdEvilYJ
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Just did this today! Eaaasy mod! Took less than an hour
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Unread 09-15-2014, 08:39 AM   #15
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I know I'm bringing this thread back from dead. But, I did this mod to my YJ .. The tube is a B!t%H to get out. But I won the battle!! Yeaaa .. for longer range between fill ups! Here is the vid:

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