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Old 01-10-2012, 01:52 PM   #1
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91 yj stock fuel tank?

Im trying to figure out the fuel sender on my 91 yj 4.0 manual. My local parts house and 4 Wheel Parts both say I should have a 20 gal poly tank with a sender that tests 0-90 ohms. Well, I have a 15 gallon poly tank, and the sender tests 22.5-93 ohms. I'm guessing he float is stuck on the low end, which I will look at when I drop the tank. I'll modifly the float if I need to.
The problem is that if I need a new sender the parts houses say they dont have the part for a 15 gal tank on a YJ. BEFORE I call the dealer, can anybody shed some light on the situation?
I'd really like my gauge to work reliably. Yeah yeah, if I crap in one hand and hope for that in the other....

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Old 01-10-2012, 01:59 PM   #2
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It should have a 20 gal tank the filler neck is longer so u would only b able to put 15 gal in it. You can shorten the filler neck so u can put 20 gal in it since you got the tank out already

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Old 01-10-2012, 02:51 PM   #3
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So if I follow you, the fill tube INSIDE the tank is long enough to deprive me of 5 gallons, but I'd I cut it, I should be good for 20? I haven't actually dropped it yet. Actually had to get some work done today.
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Old 01-10-2012, 03:19 PM   #4
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Yes it is I haven't done this mod myself yet so I can't give u specifics but there several other threads on it. From what I understand all the 90 to 95 yj's had 20 gal tanks and some they put the longer fill tube on it so it would ony fill 15, I don't think anyone understands y they did it kinda retarded to me, but they also put track bars on the front and rear axles so who knows.
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Old 01-10-2012, 04:52 PM   #5
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They did it so 15 was standard, 20 was a buyable option. But yes, all you need to do after dropping the tank is pull the vent tube out, cut it down sorter then put it back in. its that simple. Hardest part was getting the actual vent tube out of neck its pressed into. But some pliers and patience and its not too bad
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Old 01-10-2012, 07:26 PM   #6
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Thanks fellas. Any idea if the mod effects the fuel reading? Like I said originally, already having problems. Made the rookie mistake this morning and assumed I had plenty of fuel left at 140 miles...
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Old 01-10-2012, 11:21 PM   #7
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Thought I would be able to do this mod on mine, but it is for 91-95. Here is some info if you need it while the tank is out.

Jeep Wrangler 20-gallon Gas Tank Conversion
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Old 01-11-2012, 12:40 AM   #8
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Thank you. That link is great.
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Old 01-11-2012, 06:49 AM   #9
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I believe the reason they did the vent tube this way is to keep 5 gallons in the tank so the fuel pump so always wet.
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Old 01-11-2012, 08:12 AM   #10
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The tube keeps the tank from holding the extra 5 gallons, not from taking 5 out. The vebt tube allows air to be pushed out as fuel is pushed in, and air in as fuel goes out. When filling up, as the fuel.reaches the vent tube air can no longer be forced out. The pump cuts off thinking the tank is full. If you shorten the vent tube it lets,more fuel in before the pump shuts off.
20 gal tank was an option. They just used the same tank and shorter tube when someone purchased that option. Genius idea actually.
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Old 01-11-2012, 08:15 AM   #11
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Quote:
Originally Posted by Jpdot
Thanks fellas. Any idea if the mod effects the fuel reading? Like I said originally, already having problems. Made the rookie mistake this morning and assumed I had plenty of fuel left at 140 miles...
As for the gauge. Mine doesnt work, but for a different reason. but it should work fine, however it will read full or over full for longer than normal ( basically until the first 5 gallons burn) but once it reaches 15 gallons it should work same as usual
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Old 01-11-2012, 11:27 AM   #12
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Quote:
Originally Posted by rebelBullDawg325 View Post
As for the gauge. Mine doesnt work, but for a different reason. but it should work fine, however it will read full or over full for longer than normal ( basically until the first 5 gallons burn) but once it reaches 15 gallons it should work same as usual
This. You won't get the full range of motion. I.E. When you're at 15 gallons (3/4 of a tank) it will read full, and when you're at 10 gallons (1/2 a tank) it will read about 2/3 of a tank on the gauge.

I'm sure you can A: Find a float / arm for a 20 gallon, B: Make your own float / arm for the full range of the 20g, or C: Buy a new sender for the 20g.

Senders are expensive, and it all seems more than it's really worth.

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