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.

Well that sucks. I did a three inch single system on mine, with an offset/offset muffler. The tailpipe is about an inch away from the tank, so I may change the muffler to a center/center. The current muffler is too quiet anyway. :)

Original post edited to add pictures and explanation of ground wire for the fuel level sensor.

Mine is 3 inch true-dual with series 10 flowmasters(nice and loud). It is a custom made exhaust that was on the truck when I got it. It ends right behind each rear tire(you can see it in my sig photo). But when it goes over the axle, it comes back down right under each front corner of the rear tank, so it doesn't leave any room for a bigger tank, or even my full size spare :-X15

Gotta say, I like how they did the tailpipe exits. Seems like all of the less expensive exhaust kits exit under the rear bumper.

Maybe the pipes could be tweaked a bit?

I think they are about 12 inch tips welded on the exits. Probably one of my favorite things about my truck is the exhaust, I have never heard anything else like it.

When I bought the truck the PO said he got it done from stock for about $400. That included cats, mufflers, and the dual pipes. I was surprised, I thought for sure a setup like this would be a bit more $$$

I could try to see if the brackets holding up the exhaust could be adjusted lower without actually cutting pipes. I'll get under there again tomorrow and see If there is enough room to work with before I rule out this tank for sure.

Nice write up. I have done this upgrade on my truck and sure is nice for traveling.

Thanks! And I agree, this will be great for road trips.

Awesome, I was just coming on here to search about being able to use the high capacity tank on the '93 flare side I just picked up this weekend.

Excellent write up, thanks!

I'm glad you replied, I forgot to update this. I found an additional issue with extending the lines, and a quick fix.

I didn't realize that the hanger tubes have a bracket that screws to the fuel pump module, to prevent it from sliding off the tubes. I found out the hard way, my fpm slipped off the tubes, causing a no start/very low fuel pressure issue.

I made a bracket (really just a piece of stainless sheetmetal) that bolts to the original hanger tube bracket, and screws to the plastic fpm.

No problems since, and the Walbro pump is doing just fine.

Nice! I really need a bigger tank in my truck I'm always filling it every few days with all the traveling i have been doing for work and this would make it so much nicer! not to mention that my gad gauge is wrong. do you have to modify the fuel pump or is there one that can be purchased for the 38 gallon tank?I think mine is on its way out anyway so i would rather just replace it.

Thanks for sharing the pics for this project Bob Gervais!

You don't need this unless your uppper straps are rusted out, right? The 38 gallon upper straps aren't any different than the existing straps (used for the 18 gal rear tank)?

These are only needed since you're re-using your existing pump, hanger, and sender unit, right?

If my pump and sending unit is dead, I should probably just get a Bronco hanger. It looks like Motorcraft PFB4 includes the pump and hanger. The sender is Motorcraft PS22.

EDIT-
The Motorcraft part numbers I referenced above is NOT for the 38 gallon tank. They are for the 33 gallon Bronco tank (Spectra F8D).

Correct on the upper tank straps. Mine were a little rusty, and I had the bed off so I figured why not.

The bronco hanger may or may not work in this application. I think the Bronco tank is deeper than this 38 gallon tank. I had a used Bronco hanger to work with, but it didn't appear as though I could cut the required amount out of it to be able to use it.

The only modifications are as shown with the tubing on the hanger. The fuel pump is encased in the white plastic can, which I had called the fuel pump module. I'm sure there's a name for it, but that's what I called it. :D

As far as I know, there's no "drop in" replacement pump/hanger assembly that exists for using a 38 gallon tank in our body style.

You're right. My bad. I thought that the 38 gallon tank was the Bronco tank. It is not. It's an "optional" tank for the 85/86 F-series.

I wonder if the 33 gallon Bronco tank (Spectra F8D) will fit in our generation of trucks? That would enable us a drop-in hanger, pump, sender assembly.

Great Write Up Bob. With dual tanks changing the rear tank to a 38 gallon would give me 57 gallons total. At 17-19 mpg on the road that is a 1000 miles non stop for gas. Have to put a pisser in the cab I guess.
Thanks again Bob great write up.

Craig

Funnel with a hose plumbed through the floor. That's my next mod! :)

I never knew about the f26 tank until a few years ago.
I've always used the bronco tank in my trucks. My 87 up to my 95 have them. I just get the correct year for the sending unit diameter and it bolts in. Use existing straps with longer bolts and make spacers from conduit. Done it for 15 years now that way. Just modify existing sending unit like shown.

What size is the bronco tank. Someone mentioned 33 but I thought it was around 38.
Which tank is smaller in length and width, depth isn't an issue but my Reese hitch is a little inboard of the frame. ( I live in pa now but all my trucks are in Maine, I can't measure it)
I probably should replace the tank before I start building the exhaust for it. Cause I'd be pissed if I had to redo it after the fact.

Bronco tank is 32 gallon, which is also a hell of a lot better than a 19 gallon. The Bronco tank is smaller in width and length, but is deeper than the 38 gallon tank.

Nice writeup. Im thinking about converting both trucks to a single tank anyways.

Also do you have pics of the bracket you made to hold the pump onto the tubes?


I wonder if there is a 255lph pump module for these trucks at all. Gotta be a way to modify that module.

Sorry, I thought I had added that bracket photo into my original post. Here it is, nothing special really. Just some .031 stainless steel flat stock I had in the shop.

http://i223.photobucket.com/albums/d...ps8625ea00.jpg

As far as the 255lph pump module, I wasn't able to find anything back when I did this that was plug n' play like the Walbro unit. The plastic module itself can be taken apart, and it's just a normal in-tank pump inside. I'd imagine if you took some measurements you could probably find a bare pump to install in your module that was rated higher.

In my case, I had no plans on needing anything more than the stock 125lph pump, so I didn't dig into it too much.

I'm getting the 255 fdm when I replace my tank.
I've put aftermarket pumps in the stock fdm before. My 95 has 190s in the fdm.
Here's the 255lph fdm

HFP 255LPH Fuel Pump Assembly *Rear Tank* Ford F150 1990 - 1996

Bob, I know it is not online with the fuel tank, but do you have any pics of where/how they lengthened your frame?

I don't, but I can take some and send them to you.

Basically, they cut the straight part of the frame, about mid-cab, and welded in a formed channel with fishplates on the inside of the frame at either end.

Thank you for that link!

Perhaps ill pull one of the FDM's apart and see what's needed. I have a walbro sitting around.

Does this apply to brick noses or only obs?