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Old 10-06-2013, 02:17 AM   #1
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YJ Gas Tank Mod - existing 10, or 15 gallon tank turned into 20 gallon! FREE Mod!

Hey guys, today I spent a good couple hours Modifying my original gas tank to hold 175% more than the stock did! and best of all it was completely free to do.

Background Information: All 87-95 YJ models have a (roughly) 20 gallon tank installed in the rear of the jeep. Now you're probably thinking "but I can only fill 10 gallons! That's all it will hold!". The deal is, Chrysler, during manufacturing installed a ventilation tube that continues into the inside of the gas tank, which prohibits us from being able to fill past the 10 or 15 gallon mark. Why they did this, is beyond me. Probably had something to do with marketing. By removing this inner tube, you now unleash the full capacity of the tank.

You do not have to drop the gas tank, unless it floats your boat to complicate things.
You do not have to have an empty gas tank, it truly doesn't matter how full it is!

Materials:
Torx bits
Ratchet with extenders
Flat head screw driver
Needle nose pliers
**If your filler/vent hoses are rotten and cracked, now is the perfect time to replace them. Although Napa, Oriley, Auto Zone, etc. do not carry these hoses. They must be specially ordered from an aftermarket Jeep parts dealer.**

Steps:
1). The first thing to do is to disconnect the negative battery terminal from under the hood. This may seem negligible, but in reality, your tail light electrical connections are going to be in the same confined area as your gas fumes. If you choose not to do this, and your connections spark, you are playing with fire and one hell of an explosion.

2). Remove the two license plate cover/hinge screws. These screws are torx.

3). Below that is the black fuel cover shroud, this connects with three torx screws. Simply remove.

4). There are six 1/4 inch screws that you can remove with a ratchet. You may want the extender link because the shroud is recessed. Then slide out the black fuel cover shroud from the area, set it aside.

Examine). You should see a (probably rusty) metal piece, this is the hole that you put the gas nozzle in. Notice there are two holes. The bigger/lower hole is the fuel filler. While the top/smaller hole is the ventilation. Follow the hoses to the gas tank. If you got lost, there are two hoses that connect into the gas tank. The one that is the farthest forward is where gas goes in. The one that is farthest rear is the ventilation tube.

5). Remove the two black hoses from the gas tank. The tightening rings that hold the hoses on, should be 1/4 inch. Remove the entire assembly from the jeep. Leaving the two hoses attached to the metal filler nozzle.

6). On the inside of the ventilation tube connector on the gas tank. You should notice that on the inside of the protruding piece, there is a hose that has been mounted flush. This is where things get tricky; mine took two hours to wiggle loose, while some say it took 5 minutes, it's luck of the draw. Take a flat head screw driver and pry it in between the plastic gas tank, and the hose that goes inside of it. Your goal is to dis form the inner tube enough so that you can fit needle nose pliers inside and pull that darn thing out! (Easier said than done)

Note). I completely removed the hose from the gas tank. Some other posts say that they just shortened it. But in reality, there is no apparent reason it is there in the first place, other than to limit fuel capacity. Do which ever method you wish.

7). Reverse engineer. Do steps 5, 4, 3, 2, and 1 in reverse, and you should have a freshly assembled Jeep! All that is left to do is to go to the gas station and see how well it worked out for you! I could fit what I believe was an extra 7.5 gallons to my before limited 10 gallon tank!

Final Observations: the Jeep runs no different than normal. Removing this tube shouldn't affect the Jeep what so ever, other than you don't have to stop and fill up as frequently!


Note: For my protection, I am not responsible if anything goes wrong. I wouldn't intentionally hurt any Jeep!!
Happy Building!
Huntsman180

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Old 10-06-2013, 02:25 AM   #2
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Good right up but this is old news for most of us here.

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Old 10-06-2013, 03:30 AM   #3
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Originally Posted by AllMudd View Post
Good right up but this is old news for most of us here.
True, and pre 91 YJs had a true 15 gallon or 20 gallon tank. And the 15 couldn't be modified.
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Old 10-06-2013, 04:05 AM   #4
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Good write up but pictures would've made it great. There are post back to 2007 discussing this mod. always wanted to use that smilie.
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Old 10-06-2013, 06:53 AM   #5
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Quote:
Originally Posted by c5wagner View Post

True, and pre 91 YJs had a true 15 gallon or 20 gallon tank. And the 15 couldn't be modified.
Mine is a 90 and its a 10 gallon...
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Old 10-06-2013, 07:29 AM   #6
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there is no 10 gal tank, if thats all yours take you have a problem somewhere.
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Old 10-06-2013, 09:33 AM   #7
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Quote:
Originally Posted by c5wagner View Post
True, and pre 91 YJs had a true 15 gallon or 20 gallon tank. And the 15 couldn't be modified.
x2..
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Old 10-06-2013, 10:23 AM   #8
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Good written for those needing to visualize what this is all about. There is another way to get similar results and doesn't take as much work. Being an older vehicle with potential rust issues, your instructions could prevent other serious issues with the gas tank due to the rust conditions of the skid plate, mounting points, etc.

I would add to your instructions to recommend the install of a new fuel filter as well. And note this should be added to the normal maintenance action taken bi-/yearly depending on use and mileage of the YJ.
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Old 10-06-2013, 10:27 AM   #9
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Quote:
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I would add to your instructions to recommend the install of a new fuel filter as well. And note this should be added to the normal maintenance action taken bi-/yearly depending on use and mileage of the YJ.
Jagular.....you really replace the fuel filter every 6 months? Is this normal PM?
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Old 10-06-2013, 10:50 AM   #10
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Originally Posted by roadyrob View Post
there is no 10 gal tank, if thats all yours take you have a problem somewhere.
Like what?
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Old 10-06-2013, 11:32 AM   #11
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Faulty gas gauge reading? If your gauge is reading empty when it still has about 4-5 gallons left in the tank.
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Old 10-06-2013, 11:40 AM   #12
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Faulty gas gauge reading? If your gauge is reading empty when it still has about 4-5 gallons left in the tank.
That's easy enough to check. Nice long drive with a 5 gallon gas can to see how 'empty' the tank really is on 'empty'.
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Old 10-06-2013, 11:42 AM   #13
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Mine is a 90 and its a 10 gallon...
If you have a 2.5 you have a steel 15 gal. tank which can't be modified. If you have a 4.2 you have a 20 gal. tank, most likely a poly tank but it could be steel. Other than that there's a problem or a previous owner installed a smaller tank. However, a 10 gal. aftermarket tank is highly unlikely. Your fuel gauge/sending unit is probably not registering properly. In the 15 and 20 the gauge allows 2-3 gals. as a reserve.
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Old 10-06-2013, 05:01 PM   #14
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If you have a 2.5 you have a steel 15 gal. tank which can't be modified.
Aren't there Islander 2.5's with 20 gallon tanks? Mine is a 4 cylinder and I have a 20 gallon tank. Not 100% sure if its stock though, or if it was modified, but i definitely put in 19 gallons of gas the last time I filled up.
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Old 10-06-2013, 06:38 PM   #15
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Quote:
Originally Posted by kik View Post
If you have a 2.5 you have a steel 15 gal. tank which can't be modified. If you have a 4.2 you have a 20 gal. tank, most likely a poly tank but it could be steel. Other than that there's a problem or a previous owner installed a smaller tank. However, a 10 gal. aftermarket tank is highly unlikely. Your fuel gauge/sending unit is probably not registering properly. In the 15 and 20 the gauge allows 2-3 gals. as a reserve.
The tank size doesn't depend on engine size so that's a mistake there

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Aren't there Islander 2.5's with 20 gallon tanks? Mine is a 4 cylinder and I have a 20 gallon tank. Not 100% sure if its stock though, or if it was modified, but i definitely put in 19 gallons of gas the last time I filled up.
It's probably stock, many 2.5l came with 20 gal tanks
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Old 10-06-2013, 06:45 PM   #16
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Thanks for posting the write up,

here's another one for additional info:

YJ Gas Tank 15-to-20 Gallon Conversion
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Old 10-06-2013, 08:19 PM   #17
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The tank size doesn't depend on engine size so that's a mistake there


It's probably stock, many 2.5l came with 20 gal tanks
Pre-91 2.5's came with 15 gal. steel tanks.
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Old 10-06-2013, 08:46 PM   #18
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Quote:
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Pre-91 2.5's came with 15 gal. steel tanks.
Sorry, but not always true. I've seen more than my fair share of 4.2l that came stock with 15gal tanks, and 2.5l with 20 gal tanks. Tank size is independent of engine size.
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Old 10-06-2013, 09:03 PM   #19
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I wrote an almost identical article about 12 years ago. http://swbcrawler.com/tech/15to20.php
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Old 04-07-2014, 10:37 PM   #20
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Before dragging the '95 behind the motorhome from MT to S. Utah and N. Arizona, I thought it would be a good time to extend the range.

Worked out well reading the procedures here. I did add my own processes to some of the problems encountered. 1 - drilled an appropriate hole under the tailgate in the body work to get a screw driver onto the hose clamp for the vent hose on the tank connection. Yes, the factory installs the tank and clamps BEFORE dropping the body on. Now I have a hole to cover, but no biggy and better than dropping the tank. 2 - the inner vent tube was really stuck tight in the vent tank tube. I used a stiff coat hanger wire with a small sharply bent angle to fish down inside to pull (or would it be "push") the tube out of the plastic tank tube. Worked well. Put just enough tube back in to reinforce the plastic tank tube. Was down less than 1/8 tank on the gauge and filled up about 18.5 gallons so all was successful.

Now we're ready for some long dirt runs on the North Rim.
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Old 04-10-2014, 12:22 PM   #21
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All the specs I have seen on my 93 yj i6 4.0 say it comes with a 20 gl tank (I have only owned it a few weeks), but when I fill it it is full with like 12-14gls.
I also found out the hard way the gas gauge is not totally accurate, started sputtering yesterday with gauge reading 1/4 tank but then fluctuating to almost empty mark, then back to 1/4.....go figure.
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Old 08-25-2014, 10:49 PM   #22
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is there a way to tell which tank you have?

i am going to have to have some rear frame rust fixed, so it seems like a natural time to do this while the tank is down. what would you do/replace if the tank is down (88 4.2 YJ)?
- new fuel sender/pump
- remove the tube that blocks to full 20 gallon fill
- what other additional parts are needed to be replaced?
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Old 08-25-2014, 11:03 PM   #23
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Now we just need a way to tell whether the mod has been done to a newly purchased old YJ. Should be trivial, but we're not allowed to pump our own gas in this glorious state. So far, none of the pump-kids in town seems to have the patience to actually fill the tank. They just hang it up the first time it kicks off. I'm getting all kinds of weird volumes that don't match.

How does the fuel gauge behave after the vent tube is removed? Does it stay pegged on "full" until the "extra" fuel is consumed?
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Old 08-25-2014, 11:13 PM   #24
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Quote:
Originally Posted by spower View Post
All the specs I have seen on my 93 yj i6 4.0 say it comes with a 20 gl tank (I have only owned it a few weeks), but when I fill it it is full with like 12-14gls. I also found out the hard way the gas gauge is not totally accurate, started sputtering yesterday with gauge reading 1/4 tank but then fluctuating to almost empty mark, then back to 1/4.....go figure.
I have the same problem and was also wondering whatthe problem is
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Old 08-25-2014, 11:26 PM   #25
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Quote:
Originally Posted by spower View Post
All the specs I have seen on my 93 yj i6 4.0 say it comes with a 20 gl tank (I have only owned it a few weeks), but when I fill it it is full with like 12-14gls.
I also found out the hard way the gas gauge is not totally accurate, started sputtering yesterday with gauge reading 1/4 tank but then fluctuating to almost empty mark, then back to 1/4.....go figure.
The ground on the gauge usually rusts and messes up the reading. If you carry a 5 gal can of gas in the jeep and drive it until ot runs dry and refill it, it should be 20 gallons, or the previous owner swapped in a "15" gallon tank.

Quote:
Originally Posted by schwag27 View Post
is there a way to tell which tank you have?

i am going to have to have some rear frame rust fixed, so it seems like a natural time to do this while the tank is down. what would you do/replace if the tank is down (88 4.2 YJ)?
- new fuel sender/pump
- remove the tube that blocks to full 20 gallon fill
- what other additional parts are needed to be replaced?
On pre 1991 wranglers, the plastic tank is 20 gallons and the metal tank is 15 gallons. All 1991-1995 wranglers had the 20 gallon tank and some had the 15 gallon inner hose. No pre 91 wranglers can be modded to the 20 gallon tank if they have the 15 gallon tank

Quote:
Originally Posted by toddster8 View Post
Now we just need a way to tell whether the mod has been done to a newly purchased old YJ. Should be trivial, but we're not allowed to pump our own gas in this glorious state. So far, none of the pump-kids in town seems to have the patience to actually fill the tank. They just hang it up the first time it kicks off. I'm getting all kinds of weird volumes that don't match.

How does the fuel gauge behave after the vent tube is removed? Does it stay pegged on "full" until the "extra" fuel is consumed?
The fuel gauge performs like you think: full until the extra fuel is gone.
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Old 08-26-2014, 07:36 AM   #26
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Did the '95 2.5 come with a 20 gal tank that does not need modifying to hold 20 gallons? I believe I can get 20 gallons in but the pump shuts off a lot, also have a gas smell until the tank is at about 7/8 full...was wondering if the PO had made a modification.
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Old 08-26-2014, 08:26 AM   #27
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So my 88 wagoneer likely has the 15 and cannot take the 20? Is that what you're saying?
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Old 08-26-2014, 01:36 PM   #28
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Quote:
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Did the '95 2.5 come with a 20 gal tank that does not need modifying to hold 20 gallons? I believe I can get 20 gallons in but the pump shuts off a lot, also have a gas smell until the tank is at about 7/8 full...was wondering if the PO had made a modification.
The gas smell is either a bad fuel line, removed evap canister, bad gaskets on the tank or a bad fuel cap. You can always drop the tank and check to see if the modification has been done.

Quote:
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So my 88 wagoneer likely has the 15 and cannot take the 20? Is that what you're saying?
I've never owned a Wagoneer so I couldn't tell you. You can always get a 20gal tank in, but maybe the wagoneer came with a 20 gal metal tank. My above post I feel is very accurate concerning the wrangler 15 vs 20 gallon tank issue. I think I mislead in one thing and that's you can always swap a 15 gallon tank for a 20 gallon tank or vice versa. You'd need the skid plate for that size tank, the new tank, and the fuel pump or fuel sending unit for that size tank. But you cannot turn an existing pre 91 15 gallon into a 20 gallon by removing the inner hose like the 91-95 wranglers.
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Old 08-26-2014, 02:59 PM   #29
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So, as I understand from reading this.....

I have the 89 YJ 4.2 with stock tank (near as I can tell from PO's) I know two of them and I believe those are the only two POs)...

Its steel...

so that makes it a 15 gallon tank?

IF IF IF it were poly tank, then it would be a stock 20 gallon or an aftermarket tank?, right??
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Old 08-26-2014, 03:15 PM   #30
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So, as I understand from reading this.....

I have the 89 YJ 4.2 with stock tank (near as I can tell from PO's) I know two of them and I believe those are the only two POs)...

Its steel...

so that makes it a 15 gallon tank?

IF IF IF it were poly tank, then it would be a stock 20 gallon or an aftermarket tank?, right??
Correct. A metal tank is far much cheaper to replace so it's a toss up on which one is desired

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