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ghouse 02-10-2011 09:45 PM

Fuel tank conversion
Has anyone done the fuel tank conversion on a tj? Making the 15 gallon tank into a 19 gallon tank? I dropped my tank today and cut out the plastic ball in the tank. I cut far enough up to leave about 2 inches of plastic pipe. I replaced the pump/filter with a tj19. I had probably 2.5 gallons in the tank and when I filled up it only took 14.79. This is roughly 17.3 gallons. Should I have cut the plastic pipe back further closer to the wall of my tank? Is this the problem? Any suggestions would help. I'm curious how the gas pump automatically shuts off?

Shoe 02-11-2011 12:53 PM

You cut the wrong tube; you're supposed to leave the filler hose with the caged ball alone and cut off the vent tube next to it. (the vent tube is a smaller diameter hose)
But you should still have the same capacity when done. I just got done doing the same thing and haven't filled up the tank yet, so I don't know how much I gained. However I do now know how easy it is to bend the float assembly! After taking my tank off 3 times in a week to get the sender reading correct, I am now the king of dropping gas tanks!

ghouse 02-11-2011 11:37 PM

After 3 times I bet you're the king! I take it you kept the tj15 pump/filter in the fuel tank or did you swap it out with the tj19?

Shoe 02-12-2011 06:25 AM

It wasn't the original fuel pump so I'm not sure which it is. But the gauge never went all the way to full, so I'm hoping it has the 19 gal sender in it. I'm going to fill it up this afternoon and take it for a long drive, so I'll know soon.
The reason I had to drop it to begin with was after I installed a 1" body lift I noticed the gas tank straps were both broken. The gas tank skid had a date of 2002 stamped in it, so someone had replaced the fuel pump and the skid, and was too lazy to replace the straps they broke taking it apart!

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