Gas Tank swap
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Junior User
Joined: Feb 2004
Posts: 50
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From: Gresham OR
Gas Tank swap
A buddy of mine gave me a fuel tank from his '96 bronco it is about 33 gal I think. I have a '96 f-150 that I would like to put it into instead of the 18gal single stock tank on my 4X4. I do not have the spare tire under the truck as a 35" tire will not fit. Is it possable to do this swap and what other things will I need to make the switch.
Elder User
Joined: Apr 2001
Posts: 772
Likes: 0
From: Glen Burnie Maryland
Tank, sending unit/fuel pump combination, securing straps.
1.) Remove all parts of the spare tire hold-down assy.
2.) Disconnect tail lights.
3.) Unbolt bed and remove (with the help of 3-4 of your drinkin buddies)
4.) Disconnect the Fuel pump wires, fuel hose, and sending unit wires, be careful to not break the fittings, or the retainers.
5.) PUll out the old tank from the top, and remove the old straps.
6.) Wire Brush the frame and cross members in that area and coat with some kind of preservative paint. DO NOT GET into blot holes.
7.) Using original bolts, bolt to the frame members the NEW BRONCO straps.
8.) Carefully drop the tank into place. Hookup fuel pump, fuel lines and sending unit. TEST OPERATION NOW!!!!! Troubleshoot if necessary.
9.) If everything is copasthetic, put the bed back on and USE NEW CARRIAGE BOLTS (Grade-5 or better).
10) IT'S MILLER TIME!!
1.) Remove all parts of the spare tire hold-down assy.
2.) Disconnect tail lights.
3.) Unbolt bed and remove (with the help of 3-4 of your drinkin buddies)
4.) Disconnect the Fuel pump wires, fuel hose, and sending unit wires, be careful to not break the fittings, or the retainers.
5.) PUll out the old tank from the top, and remove the old straps.
6.) Wire Brush the frame and cross members in that area and coat with some kind of preservative paint. DO NOT GET into blot holes.
7.) Using original bolts, bolt to the frame members the NEW BRONCO straps.
8.) Carefully drop the tank into place. Hookup fuel pump, fuel lines and sending unit. TEST OPERATION NOW!!!!! Troubleshoot if necessary.
9.) If everything is copasthetic, put the bed back on and USE NEW CARRIAGE BOLTS (Grade-5 or better).
10) IT'S MILLER TIME!!
Elder User
Joined: Apr 2001
Posts: 772
Likes: 0
From: Glen Burnie Maryland
I did have to pull both of the low pressure pumps in my 87, so took the bed off. And yes you need the bronco pump sending unit as the tank is twice as deep and the unit installs from the top and it's twice as long.
Elder User
Joined: Sep 2002
Posts: 780
Likes: 0
From: US
I have one tip for you. I just recently tried replacing my rear tank by taking the bed off and there is no way it fits throught the top of the frame. The crossmembers around the tank are angled wider at the botom. Trust me it doesn't fit. Especially a taler tank. Just go from the bottom up.
