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Old 04-04-2016, 09:33 AM   #31
Join Date: Feb 2016
Posts: 22
Ok, about to claw out my eyes. Seems most of the front bolts are stipped at the head on top of the tank. FML! Any suggestions on how to get them out? No body or anything so it is tight up there.

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Old 04-04-2016, 11:57 AM   #32
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Why hasn't this thread been stickied yet? Shouldn't it be?

Let me tell you about Time Machine: 95 YJ Rio Grande Edition l4 2.5l on 31s stock height springs from GS, Warrior Products .5" shackle lift, Softopper tan soft top, daystar 1" body lift, Spartan locked D30, open D35 with 4.10 gearing
"Time to bust out the honky-tonk attitude"
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Old 04-08-2016, 10:15 AM   #33
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I agree, it should be a stickie.

I did this to my 91 a couple weeks ago. On my first fill-up, I got 17.5 gallons in. That was right after I did the mod, so there must've been about 2.5 gallons still in the tank before hand. I had 308 miles on the second tank and put in 20.01 gallons with the gauge telling me I was at 1/8th of a tank. So I'm guessing that either the gauge is way off and I was running on fumes, or the tank holds more than 20 gallons now.

Thanks to the original poster for posting this mod. I really hated filling up so often.

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Old 04-08-2016, 10:23 AM   #34
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I have an 89 with a 20 gallon fiber glass, square hole for the sending unit (just replaced it). Are all 20 gallon tanks fiber glass, is that a way to tell prior to 91?
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Old 01-19-2017, 12:34 PM   #35
Join Date: May 2013
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Thanks for your write up... I found out the hard way however that jeep didn't start with the 15/20 tank until 1991. My YJ is a 90' and it's 15 gallon tank is a true 15 gallon. I found this out when I ordered a replacement tank for it and it wasn't even close to fitting. A new skids plate, vent hose, filler hose, and straps were called for. But it was worth it. I got rid of my steel tank and I upgraded myself by 5 gallons.
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Old 02-04-2017, 06:57 PM   #36
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Location: Prescott, Arizona
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I did this to my '95 YJ today, but it only took me about 1/2 hour. I was able to get to the vent tube from underneath. It took a little persuasion, but I was able to get the tube out. What a joy it is to fill up my tank in 5 minutes instead of 20 minutes.
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Old 11-07-2017, 07:17 AM   #37
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Location: Northern NJ
Posts: 492
i did this mod years ago and when i did i took the filler tube out completely and left it out.... it has been working fine since... getting 20 gallons instead of 15...

the other week i had my pass rear section of frame cut and replaced so the mechanic had to drop the tank for obvious safety reasons... long story short he noticed that my fuel sending unit was rusted to hell and definitely needed to be replaced, and it did. so i told him to change it. replaced it with a 15 gallon sending unit which is fine because that doesn't affect this mod.

NOW my issue is that when i go fill up it is acting like a 15 gallon tank not a 20 gallon tank. i also tried pumping it past the fill limit and gas did come up the filler neck so i assume it really is full. But i am not getting those extra gallons i was getting prior to the replacement of the fuel sending unit. my gauge it moving past the F line way too fast.

just want to know if anyone has any ideas because i am scratching my head at this point.

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Old 11-08-2017, 01:00 PM   #38
Join Date: Dec 2016
Posts: 493
Quite likely the sender unit is shorter than the original.
Mine had been changed some time before I the jeep, I could only put 11 gallons from walk to full. Ran it out of gas, dropped the tank and still had +/- 4 gallons in it. On mine I just extended the pickup tube. Now when I'm out I can put in almost a full 15 gallons (steel tank)
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Old 11-28-2017, 09:25 AM   #39
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ill have to check that out but arent the fuel sending units all the same size for 91-95 YJ's? besides the floater

does anyone else have any ideas?
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Old 12-04-2017, 06:11 PM   #40
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15 to 20 gallon Gas Tank Modification

So I can get almost 20 gal in my ‘89, aftermarket?

1989 YJ Laredo, 4.2 carbureted, AX-15.
Small spring and body lift with 265/65-18 Duratracs w/ adapters.
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