38 gallon tank install in a 92-96 (97HD)
 

I couldn't find anything in a search on here about installing a 38 gallon rear tank in a 92-97 gasser. So, if this info is already here, whatevs. I've got pics! :)

I'll go over the parts list first:

-38 gallon Spectra fuel tank, part# F26D, about $140 at Rock Auto, and includes hardware for straps.

-Lower fuel tank straps, Spectra part #ST16, $20 at Rock.

-Upper fuel tank straps, Tank Strap, Upper 19 Gallon 80-97 (Pick Up Truck)

-Walbro replacement fuel pump module, part# TU 201. Search from Fuel-Pumps.net

-3/8 stainless tube, McMaster-Carr part# 89785K238

-5/16 stainless tube, McMaster-Carr part# 89785K229

-(2) 3/8 stainless unions, McMaster-Carr part# 5182K345

-5/16 stainless union, McMaster-Carr part# 8239K194

On to the pics:

First, remove your old fuel pump module from the hanger. Cut the red and black wires close to your old fuel pump module to make sure you have enough wire to splice in your new Walbro module. I didn't have to extend the fuel level wire, I simply unwrapped it from the hanger tubes. Walbro includes instructions on how to remove the hanger from the module. Then, cut two lengths of 3/8 tube. One will be 5 1/8", the other will be 5 3/8". The shorter one will be used for the feed. Then, cut one length of your 5/16 tube at 5 1/8". Using your unions, connect your extension tubes to your stock fuel pump hanger:

http://i223.photobucket.com/albums/d...ps0fa5522d.jpg


After your extension tubes are attached to your stock hanger, you can install the hanger into your new fuel pump module:

http://i223.photobucket.com/albums/d...psab2958c7.jpg

Walbro included crimp on butt connectors for the positive and negative fuel pump wires, but I chose to solder and heat shrink instead.

That's pretty much all of the "hard stuff", which is actually pretty simple. Spectra includes longer bolts and spacers for your fuel tank straps, from here it's just a basic tank installation.

http://i223.photobucket.com/albums/d...ps9944775d.jpg

http://i223.photobucket.com/albums/d...ps908de2cf.jpg


EDIT******

After installing everything, I realized my fuel gauge was pegged at full, with an empty tank. After some research and help from a friend, I realized that the fuel level sensor grounds via a bracket that's welded onto the hanger assembly. This bracket is moved up once you add your extension tubes in, and by doing so, ground for the fuel level sensor is lost. I added a ground wire to the assembly, and my fuel gauge works just fine now. Pics:

Stock grounding via bracket and screw:

http://i223.photobucket.com/albums/d...ps1d22d07e.jpg

Lower ground wire attachment at the fuel level sensor bracket:

http://i223.photobucket.com/albums/d...psb611e64c.jpg

Upper ground wire attachment at the hanger tube bracket:

http://i223.photobucket.com/albums/d...ps19517ab4.jpg

View of the completed assembly:

http://i223.photobucket.com/albums/d...psc7488cfa.jpg

Nice work and nice write-up. I plan to pull my bed this summer to fix my rear tank. Might consider doing this while I am at it.

Thanks Evan. It was a no brainer for me. Fuel pump died, and my truck only came with one tank.

I have dual tanks, but the rear one doesn't work at all, and not only is spare tire 20 years old and cracking, but it is a 215/75R15 I believe. In other words, COMPLETELY useless...

Yeah, I'd say so!

I forgot to include in that writeup, that you won't be able to mount a spare tire under there with this tank. I always kept mine in the bed anyway, so no biggie.

Thanks for the write-up! A lot of people ask about this mod and there aren't many comprehensive write-ups on how to do it.

How much taller is the F26D tank than the stock? I have a DMI hitch which extends below the fuel tank and I'm wondering if I have room to do this mod.

Thanks man...My rear tank leaks so I will probably try this, will let me make less trips to the gas station. That 460 is always thirsty:'(

I'd like this mod but damn I'd hate filling that thing up.

It hangs about 6" lower than the stock tank. If you need a particular measurement from somewhere on the frame, let me know!

Back in October '12, the wife and I towed my buddy's Scout out to the Saginaw area of MI. Got just about 10-11 MPG. With a 19 gallon single tank, I was stopping every 150 miles to fuel up! Great for her bladder, horrible for time. :)

Yep, the first fill up is gonna hurt for sure! But, after the initial fill up, I'll just keep throwing 40 bucks a week in it like I did before.

From comparing the ones that rockauto has,
The stock 19 gallon looks like it's 7 7/8 inches. And the 38 gallon is 13 3/4 inches. So if my math is right it's about 6 1/8 inch difference.

Hope this helps

Did you modify the arm for the float at all? Seems like it would keep the gauge showing "Full" for the first quarter/half of the tank without some modification.

Going to subscribe to this. Great write up.

I didn't modify it. I figure once it starts moving off the full mark, I'll know I have about 18 gallons or so left.

Thanks! I'll be editing my first post with another photo tonight. One thing I forgot about, is that the fuel level sensor grounds to the hanger bracket. Extending the lines removes that ground, so I'll need to add a wire in, so that the fuel level sensor works.

Good work Bob!

I'm was really considering doing this, it's a great idea and this write up makes it look pretty simple.

But then I looked under my truck today, and realized that my exhaust is only about 3 inches from the bottom of the tank :-banghead.
I don't really want to cut up the exhaust and lower it, so I may be going with the regular 19 gallon after all.