| From 1991-1995, Chrysler offered two different sized | | | | there TIGHT. In fact, removing this tube was the |
| gas tanks for the Jeep Wrangler: 15-gallon and | | | | hardest task on this project. Some people removed |
| 20-gallon. In reality, these two tanks were not | | | | this tube in sections by pulling out 3", then cutting it |
| different in size at all. The difference in some was a | | | | off, and pulling another 3" until the tube was |
| small plastic vent hose that extended down into the | | | | completely removed. |
| tank which prevented more than 15 gallons of fuel | | | | 5. Cut a 2.5" section from the liner tube. |
| being filled into them. By shortening this hose, the | | | | The fuel vent neck on the tank must have a section |
| tank can hold the 20 gallons of fuel it was originally | | | | of the liner tube pressed back inside to maintain |
| made to carry. The entire conversion process is | | | | pressure applied when tightening the hose clamp |
| about a 60-90 minute job. | | | | (during re-assembly). I have no idea why this is, but |
| | | | since someone advised to do so, I didn't argue. Cut a |
| 1. Raise the vehicle on jack stands. | | | | 2.25"-2.5" section and fit it back into the fill vent neck. |
| 2. Remove the plastic panel in the rear right corner | | | | You'll need a hammer or something heavy to pound it |
| near the gas filler. | | | | in. Make sure not to use a metal hammer should you |
| This is held in place by four plastic rivets. Remove the | | | | be unlucky enough to strike something that causes |
| rivets by securing the outer portion in place while | | | | sparks this close to the gas tank. |
| prying the center outward 0.25"-0.5" with a small | | | | 6. Reassemble everything in the reverse order. |
| screwdriver. The rivets will remove as whole pieces. | | | | Use the hose clamp to attach the fill vent hose to |
| Don't damage them because you'll need them for | | | | the fill vent neck, four rivets to reattach the plastic |
| reassembly. | | | | cover on the rear panel, and five lug nuts to mount |
| 3. Disconnect the fill vent hose from the tank. | | | | the removed wheel. |
| This is done by removing the hose clamp and pulling | | | | Unless you've installed a sending unit for a 20-gallon |
| the hose off the fill vent neck. You may need to pry | | | | tank, the fuel gauge in the dashboard will be |
| it, but it's only held on with a hose clamp. | | | | inaccurate. Others who have done this conversion |
| 4. Remove the inner plastic fuel vent neck liner. | | | | claimed the gauge won't begin to show movement |
| Inside the neck of the fuel vent hose, you can see a | | | | until there is 15 gallons in the tank. This was not the |
| tube which lines the inside. This liner tube is made of | | | | case for me. My gauge doesn't show movement until |
| hard plastic. Itýs about 9.75" long and reaches | | | | 10-12 gallons remain in the tank and when the gauge |
| about 7" into the tank. Gas can not be filled beyond | | | | reads 1/2, the tank is near empty. It used to be |
| the bottom of this tube. Shortening it will increase | | | | empty when the gauge read 1/4, but I ran the tank |
| the volume of gas that will fit into the tank. To | | | | near dry just to make certain and it is empty at the |
| remove it, you will need to pry it away from the | | | | 1/2 mark. I don't know if the sending arm got bent |
| sides with a small screwdriver and grab it with any | | | | by this or what went wrong, but it's now empty at 1 |
| small tool that offers a STRONG grip. I recommend a | | | | 2. |
| needle-nose vise grip because this tube is crammed in | | | | |