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Old 08-18-2010, 07:48 PM   #1
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Trouble filling gas tank - premature shut-off

Pretty much at every service station I've visited I find I can't just toss the pump nozzle into my Jeep and click the pump-until-its-full switch.

Whatever is telling the pump that my tank is full goes off prematurely, so I have to ride the pump, trying to figure out from the amount sold when it's really full.

In a related question: the manual says the 1987 YJ has a 15-gal tank; were there any smaller ones in production, like 10-gal?

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Old 08-18-2010, 08:37 PM   #2
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Happens to a lot of us, even with the newer Jeeps. Just get used to it.

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Old 08-18-2010, 08:40 PM   #3
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No it's not 10 gallons, I also have a YJ, but a 94, regardless i also have the 15gal tank, I also deal with this sometimes when filling up but i just assumed it's a jeep thing, by the way when I fill up all the way from empty it stops at ~13.8gallons
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Old 08-18-2010, 08:44 PM   #4
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Mine does the same, I just put in in 75% of the way and that helps.
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Old 08-20-2010, 11:08 AM   #5
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At least it's not spewing gas all over the ground like a lot of us have to deal with (youtube has videos). Every time I fill up no matter where it is I have to listen closely to it filling so I can try and let go of the handle before it spews. Sucks when the hooptie next to me has his radio blaring and I can't hear it filling.
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Old 08-20-2010, 11:14 AM   #6
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I have a '97 TJ and the samething happens to me from time to time, but not always...im not sure why, but it pisses me off so much when it does it
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Old 08-20-2010, 01:02 PM   #7
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My 06 TJ use to overfill and flood onto the ground. Took it in to the dealer 4 times and never was fixed and they replaced just about everything but the tank itself. I just had to keep my hand on the pump the whole time waiting for it to make the click just as it was going to overflow.
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Old 08-20-2010, 01:09 PM   #8
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there is a sweet spot, you'll find it.
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Old 08-20-2010, 01:33 PM   #9
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Thank you all for the replies. I'll try not to gnash my teeth too much whilst at the pump...
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Old 08-16-2011, 02:16 PM   #10
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So, a year later, I have time to let my mechanic trace out the wiring under the dash to see whether he can inexpensively undo the madness that the previous owner did. Joy, only the main wires were spliced to hell; all replaced.

On a full tank 'o gas the gauge is pegged, as expected. It says pegged until I'm about 75 miles in. Then it seems to drop in the reasonably expected fashion, altho I haven't run it dry to see the bottom point. (I may try to do that next week in the desert.)

Searching the 'net uncovers similar behaviors for folks who have replaced the stock 15 gal with a 20 gal but not finished the tweak. I haven't checked, but assuming that this is stock like everything else, what are the most likely causes?
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Old 08-24-2011, 03:42 PM   #11
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There is no 15 gallon tank. All tanks were made to hold 20 gallons, but the fill vent only allows 15. If you search for the gas tank vent modification, you'll understand more. Basically, you could pay the stealer for a "20 gallon" tank, and they just modified the vent and put in a different sending unit. If you do the mod and don't change the sending unit, the gauge will read full until you get below 15 gallons.
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Old 08-24-2011, 07:55 PM   #12
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mine has a sweet spot, if you put that handle at about 7 o clock it won't shut off till its full.

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