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Old 01-07-2012, 01:32 PM   #1
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New used tank install - fuel pump wont fit??

My 99 TJ tank sprung a leak so I bought a used replacement. The hole on the new one measures about 1/4 inch narrower, and from the bottom of the tank to the top of the threaded ring is 1/2 inch shorter on the new one?? Is there really a difference or is it because maybe it sat around in a salvage yard and the tank dimensions changed? (I dont know how much that plastic would really change with the weather??) I cant get the fuel pump in the new one. Thoughts???

Tank on the right is the original one, the tank on the left is the new used one. By eye they look identical.
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Old 01-07-2012, 01:45 PM   #2
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There is two tank sizes. Wonder if the "new" one is the smaller tank.

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Old 01-07-2012, 02:10 PM   #3
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It was sold to me as the 19 gallon which is the larger one. I guess there is always a chance they said it was 19 but its really the 15. But from everything I have read, the 2 tanks are the same physical size, the only difference is how long the fill tube is on the inside.
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Old 01-07-2012, 03:11 PM   #4
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Quote:
Originally Posted by davekippen View Post
, the 2 tanks are the same physical size, the only difference is how long the fill tube is on the inside.
I believe that is correct.
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Old 01-07-2012, 05:42 PM   #5
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Not quite clear on what is the difference but are you basing this on the fuel pump seemingly being too long to fit? If so, the fuel pump assembly is spring-loaded so you have to push down on it so the knurled ring can be screwed down into place.
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Old 01-08-2012, 07:28 PM   #6
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Even with it all the way compressed it still is too long. It will not compress far enough to where I can get the threaded ring to contact the tank threads.
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Old 01-08-2012, 08:10 PM   #7
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Quote:
Originally Posted by davekippen View Post
Even with it all the way compressed it still is too long. It will not compress far enough to where I can get the threaded ring to contact the tank threads.
It won't contact the tank threads because you have the tank sitting on the dimple on the bottom of the tank. Remove the tank from the skid and set the ends on 2x4's to let the middle of the tank sag.

As far as any other dimensional differences, that's due to your replacement tank being stored without a pump in it out in the air and as it dried out, it shrunk a bit. The plastic swells and changes shape and size a lot when it's full of fuel.

It's a very common misconception that the spring loaded part of the fuel pump assembly is there to allow the bottom of the tank to be pushed up without moving the pump up against the lockring. What is overlooked is the fully compressed height of the fuel pump assembly is the height of the tank. There is no room for it to compress when it's installed.

Also, your replacement tank may have been stored with something sitting on top of it which has caused the top to sag a bit.

Just prop the ends up and the pump will go right in.
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Old 01-15-2012, 02:06 PM   #8
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Good advice black magic! I unstrapped it from the skid plate (broke the straps in the process...) I put it up on a couple of bar stools in the garage with the middle "sagging". I turned on the salamander to get some heat on the tank, thinking it would help it become a little more pliable. It was reeeeeeaaaal close to fitting so I took some sand paper and worked the inside lip of the tank down just a hair. Not enough to screw up the seal (i hope). The combination of those things worked, I got that bastard in and locked down!

Now I just have to buy some new straps and bolt that b back in. Finally!
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Old 01-15-2012, 06:03 PM   #9
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Quote:
Originally Posted by davekippen View Post
Good advice black magic! I unstrapped it from the skid plate (broke the straps in the process...) I put it up on a couple of bar stools in the garage with the middle "sagging". I turned on the salamander to get some heat on the tank, thinking it would help it become a little more pliable. It was reeeeeeaaaal close to fitting so I took some sand paper and worked the inside lip of the tank down just a hair. Not enough to screw up the seal (i hope). The combination of those things worked, I got that bastard in and locked down!

Now I just have to buy some new straps and bolt that b back in. Finally!
I have several sets of straps if you don't find them.
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Old 01-15-2012, 11:42 PM   #10
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What year tj did the new tank come off of?

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