Jeep Wrangler TJ Fuel Tank Mod! 15 gal Tank to 19 gal! Extended Fuel Range!

[@ForceBuilt]

(My Camera)amzn.to/43y3w8w (Handy Tool)amzn.to/3PYn8zE (Fuel Pump)amzn.to/3K7HZN0 I am a member of Amazon associates. Clicking the links help me

[@eliasybarra47]

Great Video!! I love how you stopped and checked out the driveshaft while you were under the Jeep 👍🏽👍🏽 You continue to give life to Your Jeep!! Keep Wrenching Brother

[@ForceBuilt]

Thank you Elias!

[@jimzora5994]

Looking forward to the next vid, good job

[@ForceBuilt]

Thanks Jim! More coming soon!

[@andywhite2995]

Great video, these videos are great for me cause I essentially have the same Jeep and really appreciate the videos with a 4 cylinder TJ

[@ForceBuilt]

Thanks a lot. Not a ton of vids on YT for the 2.5l. Glad you find mine useful!

[@TanTanTheMan56]

Did this to my Jeep about a year ago. I used a pair of pvc pipe cutters to take the tube down, think I took a little too much off though but oh well. Replaced mine with the 19 gal fuel pump as it was cheaper then buying the 15 gal fuel pump. Only difference I notice besides the range is that the fuel gauge just stays at F for awhile until it gets back to about the 15 gal mark then it reads normally for me but man is this worth it if you have the 2.5l!!

[@ForceBuilt]

Awesome Tanner!. I love this mod also!! Thanks for watching!

[@robhdez5048]

With the 19 gal fuel pump, shouldn't the sending unit/float account for the new full level? I am guessing you might have snipped the vent tube beyond even the OEM length (which is about 1-1.5" from flush) for the 19 gal spec and you are running fat which would explain staying on full for a while B4 the 19 gal float starts registering...but I guess it's a nice feeling being on full + 😄

[@Ughandi]

just came across this video and your channel! I picked up my own TJ last year and a lot of your topics are right in line with things i'd like to do to my jeep! Thanks for the videos and keep up the great work!

[@ForceBuilt]

Welcome aboard Eric!

[@Groundedrootshealing]

Great info, doing this mod on my sons 97 2.5L. We just changed the gears as well to 4.88.

[@ForceBuilt]

That's great Jason! Mod works great just a little aggravating to do. But worth it in the end. The 4.88 really makes a difference! Thanks for watching

[@buzzlightyear7419]

Great video. My 99TJ had both the long vent tube in the tank and a float ball valve complete filling of my 19 gallon tank. I used a miniature hand saw and cut vent and ball valve off in the tank. The Mod worked great.... Thanks

[@ForceBuilt]

That's great Buzz! Cool name btw! Thanks for watching

[@SeriouslyAwesome]

hey Buzz, did you have any issues filling up since you cut out that float ball valve? Considering doing this with my 99 if I ever have a need to drop the tank

[@robhdez5048]

Hi Buzz, yes, would be interested to know how this has worked out for you a year later. Does the filler tube (ball tube) need to be cut to make this work? Cutting the filler tube and eliminating the check valve (floating ball) would/could cause an uncontrolled fuel leak during a rollover...but, I guess if I am in a Jeep with no top and no doors and get into a rollover, I probably have more serious issues to consider 😄

[@robhdez5048]

@@SeriouslyAwesome filling up should not be an issue which is why only the vent tube needs to be shortened. Removing the check valve by cutting the filler tube s likely a safety issue (fuel spill on rollover). There is a great write-up in the Jeep TJ Forum where a poster compares the inside lengths of the filler tube and vent tube in an OEM 15 gal & 19 gal tanks. Both the filler tube and vent tube in the 19 gal are shorter. From all my research, it appears that only the vent tube needs to be shortened as that is the source of trapped air (caused by the rising fuel line) that limits the fuel capacity. As long as you can vent while fueling, the longer filler tube (with check-valve) does not seem to cause an issue and does not need to be clipped. One word of caution is that many folks doing the mod, snip the vent tube too short (close to the tank opening) when compared to the 19-gal spec length. Of course, that will likely lead to a slightly increased fuel capacity & weight. Result: fuel gauge will stay on full longer and your performance may vary due to the weight. The SE is already challenged...depending on your gearing & accessory weight, could be a bigger pig. Right now, I have the 15 gal and 19 gal Delphi pumps on hand and just dropped the tank on a '98 TJ SE with a 15 gal capacity tank & original pump. Haven't decided which one I will put in. Four more gallons sounds great, but that's about another 25 lbs on a full tank. As I am running smaller BFG 30s & do not have excess weight, I am thinking I'll do the mod with little impact. It's not like I will be running on a full tank all the time. Alternatively, I am also considering clipping only about 2 inches of the vent line and throwing in the 15 gal fuel pump increasing my capacity to around 17 gallons which will be a nice boost without killing the squirrel. The gauge will just stay on full a bit longer & give me some peace of mind. Here is the Jeep TJ Forum thread with photos...scroll about halfway down: wranglertjforum.com/threads/fuel-tank-filler-tube-mod-to-convert-15-gallon-tank-to-19-gallon.12413/

[@SeriouslyAwesome]

@@robhdez5048 thanks Rob! Awesome reply.

[@Manandmachine772]

Just saw this mod glad I found it in your video list. Watching the body work series next. I believe I am going to do this mod on my 00’ I have to drop the tank to do some frame repair sounds like a good time to do it.

[@ForceBuilt]

Good deal Carl! Thanks for watching!

[@luiso6827]

Awesome video! Thanks for taking the time to explain what you were doing and how it worked.

[@ForceBuilt]

Thanks Luis!

[@nachovalenti]

Great video and really good work with that tank mate. Waiting for the next video and see how you are going to start with the body work.

[@ForceBuilt]

Thanks Again Nacho! Hope to start some body work!

[@kieferjackson8163]

This we a very useful video! Thanks for doing this. I’ve been considering doing this mod but didn’t know all that much about it so I was hesitant to do so.

[@ForceBuilt]

Glad it was helpful! Thanks for watching Kiefer!

[@KC-dz6qy]

Great info! Keep it going bud!

[@ForceBuilt]

Thanks KC!

[@edvancise]

Late to the party on this one but great video, Steve! TDSR is stock 15 gal tank and pump size with stock gearing. Ignoring the hell of rust I'll have to battle to get the tank down (and skid replacement), it sounds like this mod might not be best with stock gears. Our range is about 150 miles (12 mpg or so) but top speed is already only about 70 mph… Would be nice to go longer than a week between fill ups.

[@ForceBuilt]

Thanks Ed. My gearing probably does help. At 65mph I am running at about 2850rpm. Do you know what yours runs? The last time I checked with 32" tires, I was getting over 15 miles per gallon with the 4.88 gears. That was before the rebuild. I need to check it again. Thanks for watching!

[@edvancise]

@@ForceBuilt Took me a while to get a chance to try to go that fast… LOL! With 4.11 gears and 31” tires I hit 65 at 2650 rpm. Of course who knows if Previous Owner changed the speedo gear when he got bigger tires but GPS speed was within 3 mph so 2650 is about right.

[@rmat9023]

9:09 How is ur phone just mounted like that? Also, I have a 99 tj sport, how do I know if I have the 15 or 19 gal tank? Some people said it has 19 but the pump only sends 15 or something. hm...

[@ForceBuilt]

I have a magnetic phone mount. The part # for the fuel tank is visible on the driver side of the Jeep. Type that # into Google and it will tell you. Thanks for watching!

[@rmat9023]

@@ForceBuilt where in the driver side? in the door jamb? I have no stickers or anything there.

[@ForceBuilt]

@@rmat9023 On the fuel tank itself.

[@rmat9023]

@@ForceBuilt oh, so i found the sticker it was at the side of the dash board. And it had the VIN, which apparently if u have a 98 or newer, there are sites that can give u the build sheet. With that said, it told me I have the 19, but in driving, when I get to the red section of the fuel indicator, I got almost to the E but when I gassed up it only took 13 gallons.

[@ForceBuilt]

@@rmat9023 My now 19 gallon when at the red point you mentioned, I can sometimes get 14 gallons in. So yours is right. No need to mod yours.

[@leonardovillalba881]

Great video !!! Thanks pal

[@ForceBuilt]

Thanks Leonardo!

[@tylerlondon5052]

You just saved me $20 on a spanner.

[@ForceBuilt]

Good deal Tyler!

[@hhyperdd]

Great vid, sir... I think I'm gonna let my '06 run out, add a gallon, then drive it to gas station, where I'll confirm what its capacity is, before I take this tank mod journey.

[@ForceBuilt]

Good Idea!

[@codyhilburn9203]

Very informative. Thank you!

[@ForceBuilt]

Thank you Cody! Glad you liked it!

[@bobweiss2941]

My 97 TJ 2.5 has 140000 miles on it. Thinking I should drop the tank and replace the pump before it’s leaves me sitting somewhere. Great Mod to consider doing. Thanks again!

[@ForceBuilt]

Thanks Bob! I would keep running it if it were mine. Unless it was showing signs of failure. Thanks again!

[@dannyb78]

You mentioned you have 4.88’s. I’m actually taking my jeep next week to have the same 4.88’s installed in my jeep, hows your get up and go with those gears ? And what is your tire size your running ?

[@ForceBuilt]

I run 32x11.50 15r. I have no experience with the 2.5L without these 4.88 gears. So I don't know how bad stock gears are. It isn't a power house but I can get to the speed limit in a reasonable time. I normally cruise at 65mph running just over 3k rpms. Max speed is 80 mph. I can run 70 no problem. We took a 400 mile trip to the Jeep Invasion in Gatlinburg TN. I ran 65-70 there and back not problems. I am getting 16-16.5 miles per gal fuel economy. I love my Jeep the way it is. It is plenty powerful enough. Thanks for watching!

[@dannyb78]

@@ForceBuilt thank you sir, I too love my jeep and it has exactly what you have except I’m running 33’s. My gear guy said I should go with the 4.88’s. I was gonna go with 4.56 which would get me pretty close to stock again but I’m going off what my gear guy is telling me at this point lol 😂. I think the 4.88’s will give me a little bit more than the 4.56 gears. Guess we will see. Thanks again.

[@dannyb78]

@@ForceBuilt oh I did install a header and a cold air intake so hoping that will help as well !

[@sg1trogdor]

I know this videos several years old but where the hell do you live that it was $1.29 a gallon. I havent seen prices that low in my area in over 20 years.

[@ForceBuilt]

Hahah, North Mississippi. We at $2.89 at the moment. Thanks for watching

[@johncena2336]

Replaced my fuel pump, before fuel only went to 3/4 on the gauge. After the replacement, it finally went to F.... For 2 weeks.. Now it’s only going to 3/4 again.

[@ForceBuilt]

Yeah, that's strange. I wonder if you new pump has a faulty sender?

[@mulekicker-ut5jl]

I bet PCv ratchet cutters would work good for that

[@ForceBuilt]

Yes, that would be perfect!

[@mulekicker-ut5jl]

@@ForceBuilt I have a 97 wrangler tj and I’m about to change the fuel pump. I noticed for some reason the 15 gallon pumps cost more than the 19 gallons. I don’t know if my pump is original or what but I’m buying the 19 gallon and will modify. Thanks for the video.

[@ForceBuilt]

@@mulekicker-ut5jl very welcome! Good luck with the awesome mod!

[@Pete-from-Tn]

Mine has the 19 gallon tank, so guess I will not need to do that mod. I'm going to also put new fenders on mine. Add AC as it did not come with AC. New front winch bumper. Looks like my 97 has 2700 more miles then yours. Thinking if I can get mine in to the local vocational school body shop. Going to let them paint it, if not I will do it myself.

[@ForceBuilt]

Pete that's great! Good luck with your project!

[@brianbritton6555]

How do you know if you have the 15 gallon tank and the 20 gallon tank or is it just the 15 gallon tank is there two different tanks. And when I fill up my tank always goes to full how do you know what fuel pump you have

[@ForceBuilt]

The tanks are the exact same physical size. The only difference is the length of the vent tube. That is why I cut part of mine off in this video. I wish I had cut off just a little more. If your Jeep is a 2.5l 4 cylinder it most likely will be a 15 gallon tank. Concerning the fuel pump. If you have a 20 gallon fuel pump in the 15 gallon tank, it will never show full because the long vent tube will keep the tank from filling up all the way. So the 20 gal fuel pump will never show full but a 15 gal fuel pump will(this was my situation because of previous owner). If you do the vent tube mod like I did in this video, you can leave the 15 gal fuel pump in the tank. The only side affect is that the fuel gage will show full too early(when filling up) and show full too long(when the gage should be dropping while traveling). This doesn't cause a problem just expect the fuel gage not to move down for many miles after a fuel up. Once it starts moving down it is still accurate to refuel by(meaning it will go all the way down to empty on the gage) I hope this makes sense.

[@donmccune2583]

So your mod. I don’t have to buy a 19 tank just cut the tube out? My gauge is doing the same thing only gos to 3/4 when I fill up.

[@ForceBuilt]

That is correct. You seem to have a 19 gallon fuel pump in your 15 gallon tank. Yes, just cut the tube and you will be able to fill all the way up. Thanks!

[@coachgeo]

two questions if you don't mind... If someone had a 3inch body lift..... will that change ability to do this without removing the tank? If one was thunking long term ahead and decided to cut a square out of the rear tub to make an access panel there for diagnosing and R&R fuel pump (and doing this mod) how big a spot you think would be needed? Maybe rectangle so can get a bar in to tap the screw in pump cap to assist it unscrewing it?? Got an approx idea where to cut it?

[@coachgeo]

well... answering my own question LOL (tank access) found below kzbin.info/www/bejne/hpnKeGaqjZ6coMU

[@ForceBuilt]

The gas tank will have to come out even with a 3" body lift. The other question I don't have any information for. Sorry

[@captainbc52]

How do you tell what kind of fuel pump you have? I have a '98 TJ 2.5 that's had a couple owners before me that did mod out a lot of things. The most I have ever filled up with with my gas light on is 11 gal. The needle always goes to full but I only get around 150 mi to the tank.

[@ForceBuilt]

With the info you provided you have a 15 gal pump. If it was the 20 gallon one it would not show full with only 11 gallons held after fuel light is on. A 20 gallon pump in the 15 gallon tank you have will never show full until you do the mod that I did in this video. A 15 gallon pump(That you have) after this mod will show full for many miles before the fuel gage starts to move toward empty. That is not a problem just expect it to show full longer than usual. Thanks!

[@---rg1gb]

@forcebuilt. So how many gallons can you actually put in the tank now from fully empty. 19 as expected or less?

[@ForceBuilt]

I would say I hold around 17.5 or 18 gallon now. I could have cut more off the breather tube. The full range added about 50 miles which is a good bit. Thanks for watching!

[@joshnasche5495]

Wonder if that could work for a YJ wangler?

[@ForceBuilt]

Yes it will! I am sure the the breather tube will come out from the outside on yours. It's like a smaller tube inside the breather tube. Try and grab it with needle nose pliers and pull it out. Cut off about 4 inches and push it back into the breather tube hole.

[@Gunmetalbluejeeptjs]

How much do you have to take off of the breather tube

[@ForceBuilt]

About 4".