FREE Fuel Capacity Increase 1991-1995 Jeep Wrangler YJ 

I own a Wrangler. Did this mod about 8 months ago. It works great!

My 99 Wrangler TJ had a 20gallon tank but the 6" of extra vent line dipping into the tank was re-engineered so it was no longer an plastic insert that could be pulled out of the vent line from the top filler side. Also Chrysler added a ball type float valve to the filler line to prevent the tank from being filled beyond 13 gallons. To make this mod to my fuel tank I had to drop and drain the the tank. Then I reach in the tank from the fuel pump hole and cut off both the extra vent line and ball valve using a miniature hand saw. The whole operation took 4 hours but the results were awesome. Now I have a usable 20 gallon tank and don't have to carry a gas can with me when I go wheeling. Thank you for your very helpful video.

Looks like I now have something else to do this weekend. Thanks Dale!

Thanks for your videos. In your video on relacing the exhaust system.I was replacing the tail pipe only on my 95 wrangler. You said you had to drop the track bar. I found if you go over to the opposite side ( drivers side their is room the get the tail pipe over the track bar . Then just work it over to the passenger side. But my gas tank was removed. Thanks again for your videos. 8/12/23

Well that explains why the owners manual says 15 gal, but I can put in 17+ gal at fill up...thanks for the info! Love the channel.

I’ve been waiting for this man 17 just a bought a 94 so brilliant

Thank God for your great explanation. I have been going crazy trying to figure out which sending unit to order. Thanks so much

Dale, well done...AGAIN! Thanks for another vid. Stay safe out there

When i first started watching your channel I though it was kind of bland but informative, now your making it interesting to watch with your humor!! Thanks Dale!

If you drop the whole tank it's a lot easier and you can also remove a couple bends from the fill level float rod so that the gauge reads right. I hear if you cut the vent tube too short the pump handle at the gas station won't stop on time and you'll spray yourself with gasoline.

Hey Dale thanks for pulling out the white board & explaining it better. Bc I was utterly confused as to how you would gain 5 more gallons just by cutting the vent hose! LOL! I wonder what the original cost of upgrading to the 20 gal version cost a customer back then. That's just shady imo since it's just smaller hose instead of bigger gas tank. I don't comment often but you are my favorite Jeep guy. I always think oh has Jeep Solid got a video for that if I'm looking for something on my 94 YJ!

thanks dale looks like i have a another project to do on my yj

I did this to my 94 wrangler. It does hold 20 gal. I didn't upgrade sending unit so I drive 80 to 90 miles before fuel gage starts moving off full. 😎

Great info . ( it’s just I never understood why someone would stop for 5 or 10 gallons of gas instead of topping it off? You only have to return to the pump sooner )

Very helpful video. Thank you for the thoroughness and explanation. Take care.

Wow awesome . Gotta try it myself soon

Why did Chrysler put in a longer vent hose than needed? Was it for safety or fuel economy (less weight to haul around) or was it actually just a matter of allowing them to sell additional capacity as an upgraded feature? Are the Jeeps that came with a 20 gal capacity exactly the same except for the length of the vent tube? I honestly find this difficult to believe. Seems exceptionally sleazy, if true. Edit: I did a bit of research and it turns out they did it to meet Federal fuel efficiency regulations. With the 15 gallon restriction their vehicles had better gas mileage.

Ok my 92 has never held over 16 gallons. But the fuel gauge will stay at full for along time after I fill the tank then when it says 1/4 or a little less it will run out of gas…

Thank you so much next project

It's actually 91-2006 the tj's are the same

Do you have to do anything to get the gauge to read right after this?

Quick question: So when you shorten the vent tube, do you have to get a new sending unit so it registers Full and Empty correctly?

YJ самый настоящий рессорный и красивый вездеход

Wonderful explanation.

Great Video, Thanks

WoW,, does this apply to a 1990 Jeep wrangler? I know you are saying 91' to 95... is it possible?

I know this is old but thought id ask. Would this work for the older CJs? I have a 79 with the metal tank.

When your done on this jeep it may become the keeper. Lol. Thanks for the video's.

Great!!! Thanks for the awesome videos you make 👍

What about the room for expansion when its hot?

Jeep Solid , haciendo eso hay una diferencia de 20 litros mas en el tanque y un mayor rendimiento

Thanks for the reply! Here's what I've got. 1993 YJ Sport 2.5l 3" Body Lift - Unknown Brand 4" Shackle Lift - Unknown Brand 33" Tires. My Leaf Springs are flat, so those need replacing for sure, only thing is, I would like to lose the long shackles as they are like 6" long, and go with greasable boomerangs from rough country. Aslo, while adding the boomerangs, I'm thinking of going with a 2 or 2.5" lifted leaf springs, (cant find 2" Rough Country anywhere?), and dropping tires back to 30 A/Ts I had to do alot of research in finding out if I can just do all this without any special changes to what I have in place for other suspension components ie; tierods, drive shafts, brake lines? and stuff. with the boomerangs 1.25"-1.75" 2.5" lifting leaf springs 3" body lift left as is and 30" tires what height would I be at, and does this all seem safe and feasable for street with the 2.5l and stock axles/ratios? Open to comments, guidance, and pointers. No I do not want to mess with the body lift after all the videos ove watched, it just seems like a can of worms I'm not willing to open yet. All the body lifts look good, but i dont want to run into another thing holding me back from whats beginning to be a beautiful summer and my first very own YJ to cruise in. Tie rods, steering stab, and shocks are all on the list to be replaced, but again, not sure If I need to go with specifically due to my particular lifts and whatnot. What else am I missing and should be taken into consideration? Alot of play in steering so shaft is on replace list as well. I drove it home with bald-ish 33" mudders, definitely had some floating going on, but I assume that will correct when I drop a little and get the 30" All terrain Tires on it, and take care of the other suspension and steering components. I'm all ears, thanks for being here for us Dale, you are great! David S from Maine

4 cyl didn’t need extra weight so had 15 gal. 4.0 and4.2 didn’t care so had 20 gal. Goes back to 87 yj

So much easier than dropping the tank

Thank you!!!!

Nice video 👍 definitely have to subscribe

Great vid pal!!!

Is there a way to tell if you have the 20 gallon upgradeable tank without dropping it? Were they all 20 gallon tanks by default, but you got the 15 gallon tube if you didn't pay for the upgrade?

I opted to not cut my inner vent hose and put in a shorter hose. I just left it out. I haven't had any issues, but curious if there could be a problem with doing it that way?

what happens if you take out the hose and just throw it out instead of cutting it? I didint watch the video fully and just threw the hose away.

So my YJ is an 89, will it have the 20 gal tank?

Am I wrong or did I see your leaf spring digging into your frame?

The small channel locks will be right next to the 10mm socket! Any more thoughts on the JK?

Rookie question: My YJ with the stock "low capacity" tank fill registers "FULL" on the fuel gauge at the lower capacity (12-14 gallons?). After this mod, will the gauge register full at the "old" fuel capacity, or will it also reflect the percentage full at the new capacity?

Does this mod work on a 2003 TJ ?

Does this work on an 87 YJ?

My 90yj has a 10gal. metal tank.a friend gave me a 15gal metal tank.is it possible to do that mod to it?

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I think I may need to replace the fuel pump on my 95 YJ. I've seen several videos where people have cut out an access panel on the inside of the vehicle to access the panel on the top of the tank. My Jeep body is lifted, so this would definitely be doable and rather straightforward for me, but this 'mod' strikes me as a bit sketchy (and possibly illegal?). What are your thoughts on this?

What about an 1988 yj

Goes back to 87

Do you still have full service gas stations out there?

Super easy mod, but just shows the shitty means to which manufactures will go to squeeze cash out of consumers