Gas tank mod on 1991 to 1995 YJ's

[XJMJeep]

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

http://i1205.photobucket.com/albums/bb432/XJMJeep/Tank%20Mod/100_1359.jpg

After its out this is what you have

http://i1205.photobucket.com/albums/bb432/XJMJeep/Tank%20Mod/100_1348.jpg

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

http://i1205.photobucket.com/albums/bb432/XJMJeep/Tank%20Mod/100_1358.jpg

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

http://i1205.photobucket.com/albums/bb432/XJMJeep/Tank%20Mod/100_1354.jpg

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

http://i1205.photobucket.com/albums/bb432/XJMJeep/Tank%20Mod/100_1344.jpg

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!

http://i1205.photobucket.com/albums/bb432/XJMJeep/Tank%20Mod/100_1343.jpg

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

http://i1205.photobucket.com/albums/bb432/XJMJeep/Tank%20Mod/100_1366.jpg

Cut the tube down to about 2 1/2"

http://i1205.photobucket.com/albums/bb432/XJMJeep/Tank%20Mod/100_1335.jpg

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. :rotfl2:

http://i1205.photobucket.com/albums/bb432/XJMJeep/Tank%20Mod/100_1350.jpg

Job well done!

http://i1205.photobucket.com/albums/bb432/XJMJeep/Tank%20Mod/100_1367.jpg

Remember there are sharp edges under there!

[XJMJeep]

Follow up after the mod.
When the pump kicks off, it's full!
Trying to round to the nearest dollar will result in spillage. :o

[Mudderoy]

Follow up after the mod.
When the pump kicks off, it's full!
Trying to round to the nearest dollar will result in spillage. :o

Sounds like it was a successful mod!

[usramc]

I just got my yj, it was on a quarter tank so i filled it up, held 16.8 gallons, so im assuming mines already done.