Gas tank mod on 1991 to 1995 YJ's - WranglerTalk -Jeep Wrangler Forum
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Old 05-26-2012
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Default Gas tank mod on 1991 to 1995 YJ's

This is a simple modification, takes about an hour and adds 5 gallons to the stock 15 gallon tank on 1991 to 1995 YJ's

This is how I did it, you can figure out the best way that works for you.

First remove the left rear tire (driver side)

Next there is a small cover held in with 4 plastic rivets, remove the rivets with a small pair of needle nose pliers.
They are reusable so take it easy on them when removing

After its out this is what you have

Next remove the license plate and bracket.
The bracket has 2 screws and are a Torx T20

Now remove the filler tube housing, 6 - 8mm screws and 3 Torx T20 screws and it's out

This hose clamp is in an awful location but with a little work it comes loose

Now the "fun" part.
Inside the return tube is a smaller tube that is about 9" long.
This tricks the gas pump into thinking the tank is full when there is still 5 more gallons of space.
Gotta get it out of there!

I wedged a small flat head screwdriver between the two pipes and bent it up enough to get a pair of needle nose pliers between them.
After pulling and slipping, bleeding and cussing, I figured out it was easier to grab hold and twist the pliers a few times then pull.

It mangled the tube but it came out

Cut the tube down to about 2 1/2"

Then reinsert it.
I'm not sure if this step is even needed but I did it anyway.

Put everything back together and enjoy your extra 5 gallon capacity!
Our cat helping with the reassembly.

Job well done!

Remember there are sharp edges under there!
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1991, 1995, add, gas, mod, tank
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