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Old 12-02-2008, 02:17 AM   #1
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Wierd TJ Fuel Capacity Problem??? Halp!!

I have owned my TJ for a couple months now and have never been able to fill it past the 3/4 mark. At first I thought that the gauge was messed up but after a few fill ups I found out that it is working fine. My Jeep does have a 2'' body lift that the previous owner put on. Would this have anything to do with my problem? Is it possible that a line was stretched or squished? I tried filling up really slow last time but still only got 3/4 the way. Please help!

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Old 12-02-2008, 02:53 AM   #2
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dam i have the same problem and never thought about it... hope someone knows the solution

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Old 12-02-2008, 03:47 AM   #3
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Yeah, i have the same problem and i always thought it was my gauge -- maybe its not.
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Old 12-02-2008, 08:31 AM   #4
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my gauge goes to full but when it gets down to 5 gallons in it the gauge doesnt read anything and the dummy light comes on.
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Old 12-02-2008, 08:38 AM   #5
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I have the same problem too. My shop thinks that the fuel gauge sender may be bad. That's the toilet float in the gas tank. They said that sometimes when the floats get old, they partially fill with water. If they do this, the gauge will read 'not quite full' even if it is. If that's the case, then when the gauge reads empty, the tank really may not be. It's a drag because I have to fill up often and never really know if I'm about to run out of gas when it's on empty. To replace the sender, my shop said that the tank needs to be removed in the Wrangler so, it's a fairly big job. I'm considering it. Of course, the problem might not actually be related to the sender.

Any other thoughts?
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Old 12-02-2008, 08:51 AM   #6
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what i did when i replaced mine i cut a hole in the floor and bolted a plate now all i have to do is remove the plate and not drop the tank again.
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Old 12-02-2008, 08:54 AM   #7
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what i did when i replaced mine i cut a hole in the floor and bolted a plate now all i have to do is remove the plate and not drop the tank again.
Was a bad sender the cause of the problem? And did replacing the sender fix it?
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Old 12-02-2008, 08:57 AM   #8
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no it didnt fix the problem it still shows below e with 5 gallons in the tank and i just go 50 or so miles after that and than fill up. its a jeep thing i guess
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Old 12-02-2008, 09:06 AM   #9
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By the way, what is the capacity of the TJ fuel tank? Mine is a 2000.
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Old 12-02-2008, 09:07 AM   #10
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19 gallons
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Old 12-02-2008, 09:49 AM   #11
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Sorry guys and gals to say this but "IT IS A JEEP THING,GET OVER IT" Nauh I think all of us that are supposed to have the "19 gallon tank" has this same problem.Mine is the same way.I find it hard to get the gas to start flowing without kicking it off at first but once I get it going then it kicks off before it is really full.I have sqeezed that extra dollar($3 when gas was really high)in it before just to show full on the guage for about 2 seconds on start up then back to just above 3/4
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Old 12-02-2008, 11:12 AM   #12
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Did the TJ's have this problem when new? If so, does replacing the sender solve the problem?

I just filled up when the gauge read just over 1/8 full. I was able to squeeze 12 gallons into the tank -the gauge now reads 3/4 full. I don't really know how full the tank is now or when it reads empty.
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Old 12-02-2008, 04:38 PM   #13
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if it has a body lift you may have put on a fuel filler extension if that is not runnin at the right angle or is pinched it may not let you fill it all the way up....i had that problem until i stretched my jeep and put the tank in the bed
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Old 12-02-2008, 04:45 PM   #14
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My TJ has the problem it is not lifted. My shop wants to replace the sender unit. I need to know if this will solve the problem??
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Old 12-02-2008, 05:43 PM   #15
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I don't think replacing the sending unit will not do any good! I have read that cutting part of the filler neck off so it doesn't go as far into the tank will make you go from a 15 gallon tank to a 19 gallon because they use the same tank on all, but is that true??? Maybe and if so I do believe this has something to do with those specified as a 19 gallon tank not showing full when they are. I have not found it to be that much of a problem or at least not enough to replace a pricey fuel pump and sender because to my knowledge the sender and pump only come as a unit assembly.I don't think you can buy just the sending unit but then again I have not checked for just it alone.It isn't like to older senders that were steel and rusted out after a while.
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Old 12-02-2008, 05:50 PM   #16
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i would say drive it till it breaks and replace it then u r gonna have the same problem still just like mine. if u have it done cut the hole in the floor above it and wont have to pay so much to have it changed if it needs it again. when u cut make sure the gas tank is removed. dont do like my buddy and cut into the tank good thing its not metal.
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Old 12-02-2008, 05:55 PM   #17
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Kylebgt,

with the tank empty, how many gallons can you pump into it, whats the gas station pump say?

fyi... After I drive around on E for about 20+ miles, the most I can get into my 19 gal tank is still only about 16 gallons. That is pretty normal.

if you still think your tank has a problem check to see if the factory skid is dented. After I dented my stock skid a bunch I could only fill it part way because the tank was deformed. After I replaced the skid that problem went away. It is possible to damage the sump/sending unit from a badly indented tank. That may be another culprit.
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Old 12-02-2008, 06:34 PM   #18
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Quote:
Originally Posted by slf41002 View Post
I have read that cutting part of the filler neck off so it doesn't go as far into the tank will make you go from a 15 gallon tank to a 19 gallon because they use the same tank on all, but is that true???
You are correct. There is a guy in the Club here in town that has done that.
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Old 12-03-2008, 01:30 PM   #19
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All this time I thought I was crazy...the fuel light would come on and for g&g I drove until the arm went to the farthest regions of E...I filled up and dam...18.1 gallons...and all this time I thought it was only a 15 gallon tank!!
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Old 12-03-2008, 04:00 PM   #20
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i just filled up after running below e for 70 miles(carried spair gas can) just filled up and took 18.2. got 320 miles and only got 17.5 miles to the gallon. i say only cause at 60 on the freeway i can push 21 mpg. only thing i have to say i love the edge trail jammer.
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Old 12-03-2008, 04:13 PM   #21
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Early TJs had a recall on the fuel gauge sender, maybe some of you guys can get them replaced for free by the dealer. My '97 was one affected by the recall.

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