Jeep Tj Gas Tank: Mounting And Installation Guide

The Jeep TJ gas tank is mounted under the rear of the Jeep, with the factory fuel sending unit and filler neck attached. The tank is secured in place using stainless steel straps and a skid plate. The skid plate is made from heavy-duty steel and is powder-coated black. The tank can be accessed by removing the cover plate in the rear cargo area floor.

Jeep TJ gas tank mod

The Jeep Wrangler TJ is a popular model for off-road enthusiasts, and there are several modifications available to upgrade the fuel tank and improve its performance. Here is a guide to some of the Jeep TJ gas tank mods available on the market:

GenRight Crawler Enduro Gas Tank

The GenRight Crawler Enduro Gas Tank is a direct bolt-in replacement for the factory Jeep fuel tank. It has a capacity of 24.5 gallons, which is an extra 5 gallons over the stock tank. This allows for longer trips without worrying about refuelling. The tank is made from 1/8" thick aluminum alloy and is TIG welded for superior strength. It includes a matching heavy-duty skid plate and a foam liner between the tank and skid plate for added protection. This mod is designed to fit Jeep Wrangler TJ or LJ models from 1997 to 2006 with the rear axle in the stock location.

Barnes 4WD TJ Stretch Fuel Tank

The Barnes 4WD TJ Stretch Fuel Tank is designed for Jeep Wrangler TJ models from 1997 to 2006. It allows for a rear suspension stretch while retaining an underbody-mounted fuel tank. The tank is made from fuel-rated plastic and has a capacity of approximately 13 gallons. This kit includes everything needed for installation, including a 3/16" bare steel flat bottom skid plate. It works with factory axles and a 1-ton axle, and it can be stretched from 0" to 9" with the factory axles and 0" to 8" with a 1-ton axle.

Motobilt Stretch Underbody Fuel Cell

The Motobilt Stretch Underbody Fuel Cell is designed for the Jeep Wrangler TJ or LJ models from 1997 to 2006. It offers a wheelbase stretch of up to 6" in the rear, depending on the axle. The fuel cell has a capacity of 14.5 gallons and is made from 1/8" thick aluminum sheet that is precision CNC laser cut and CNC press brake formed. It features a TIG welded aluminum fuel cell for superior weld strength and finish. The kit includes a heavy-duty 3/16" steel skid plate and all the necessary hardware for installation.

OEM Fuel Tank Skid Plate

The OEM Fuel Tank Skid Plate is a factory replacement part for the Jeep Wrangler TJ models from 1997 to 2006. It is designed to protect the fuel tank from debris and damage during off-road driving. The skid plate is made from durable materials and is a direct fit for the stock location. It is available from various manufacturers, including Mopar and HECASA.

Rugged Ridge Gas Tank Skid Plate

The Rugged Ridge Gas Tank Skid Plate is an aftermarket option for the Jeep Wrangler TJ models from 1997 to 2006. It offers additional protection for the fuel tank and is made from heavy-duty materials. This skid plate is designed to be a direct fit for the stock location and is a popular choice for off-road enthusiasts looking to upgrade their Jeep's underbody protection.

Jeep Wrangler gas tank skid plate

The gas tank on your Jeep Wrangler can be vulnerable to rocks and other objects when off-roading. A gas tank skid plate can protect it from harm and give you peace of mind. There are a variety of options available for the Jeep Wrangler, which vary depending on the model year of your Wrangler and the number of doors it has.

Jeep Wrangler JK 2-Door

Rough Country offers a gas tank skid plate for 2007-2018 Jeep Wrangler JK 2-Door models. This product is made of 3/16" plate steel and features a black powder-coated finish. It includes mounting brackets and hardware for a bolt-on installation. The estimated install time is 1-3 hours and it is backed by Rough Country's lifetime warranty.

HECASA also offers a gas tank skid plate for the same Wrangler JK 2-Door models. This product is also made of steel and features a black powder-coated finish. It includes the necessary hardware for installation.

Jeep Wrangler JK 4-Door

Rough Country offers a gas tank skid plate for 2007-2018 Jeep Wrangler JK 4-Door models. This product is made of 3/16" plate steel and features a black powder-coated finish. It includes mounting brackets and hardware for a bolt-on installation.

Jeep Wrangler TJ & Unlimited

AccuPart offers a fuel tank skid plate for 1997-2006 Jeep Wrangler TJ & Unlimited models. This product is made of steel and features a black finish. It includes the necessary hardware for installation.

Dorman offers a fuel tank skid plate guard for the same Wrangler models. This product is constructed of steel and features a black painted finish to fight off rust and corrosion. It features a bolt-on installation process, utilizing existing mounting holes.

Kojem offers a fuel tank skid plate guard for the same Wrangler models. This product is a direct replacement for the original skid plate and is made of steel with a black finish. It includes the necessary hardware for installation.

KUAFU offers a fuel tank skid plate guard for the same Wrangler models. This product is made of steel with a black finish and includes the necessary hardware for installation. It is a direct replacement for the original skid plate.

Other Options

There are also gas tank skid plates available for other models of the Jeep Wrangler, including the YJ, JL, and CJ. In addition, there are skid plates available for other Jeep models, such as the Cherokee and Grand Cherokee.

Jeep TJ/LJ Crawler™ EXT Gas Tank & Skid Plate

The Jeep TJ/LJ Crawler™ EXT Gas Tank & Skid Plate is a heavy-duty replacement for the factory Jeep fuel tank. It is hand-fabricated to allow for more clearance between the rear axle and the gas tank, enabling you to lengthen your Jeep's wheelbase while maintaining the same fuel capacity as the stock tank. This tank is designed for those who want to upgrade to bigger axles and accommodates a wheelbase stretch of up to 5" with a Dana 44 axle.

The tank is made from 1/8" thick Aluminum alloy and is hand TIG welded to ensure durability. It includes a foam liner between the tank and the skid plate, which is made from 3/16" thick heavy-duty steel and powder-coated black for added protection. The tank is assembled with stainless steel straps and includes factory Mopar roll-over/vent valves to prevent fuel leakage during off-road adventures.

The Jeep TJ/LJ Crawler™ EXT Gas Tank & Skid Plate is designed to mount in the stock tank location under the rear of the Jeep, keeping the center of gravity low. This mounting location also provides 1" more ground clearance than the stock tank and an improved departure angle. The tank has a capacity of 19.5 gallons, allowing you to stay out on the trail longer without worrying about running out of fuel.

The tank reuses all the factory EVAP connections and the factory fuel pump module, ensuring that you won't encounter any check engine lights or computer issues. It is compatible with Jeep Wrangler TJ/LJ models from 1997 to 2006. Installation may require changes to the last 14" of the exhaust tailpipe and a small body lift for 2003 or newer Jeep models.

Jeep TJ fuel tank stretch

The Jeep TJ fuel tank stretch is a modification that can be made to a Jeep TJ or LJ to increase the wheelbase and improve off-road performance. Stretching the wheelbase involves moving the rear axle further back, which requires relocating or modifying the fuel tank to make room for the larger axle.

There are several options for achieving a fuel tank stretch on a Jeep TJ, each with its own advantages and considerations:

Aftermarket Stretch Fuel Cells

The most common approach is to install an aftermarket stretch fuel cell, such as those offered by GenRight, Motobilt, or PureJeep. These fuel cells are designed to provide more clearance between the rear axle and the fuel tank, allowing for a wheelbase stretch of up to 7 inches, depending on the brand and axle configuration. They are typically made from heavy-duty materials like aluminium or steel and offer larger fuel capacities than the stock tank. While these options can be more expensive, they provide a reliable and safe solution for those seeking a significant stretch.

Modifying the Stock Tank

Some Jeep TJ owners have opted to modify the stock fuel tank to create more clearance for the rear axle. This involves heating and reshaping the plastic tank to match the contours of an aftermarket skid plate with a reverse bump designed to accommodate the larger axle. While this method can be more affordable, it requires careful execution to avoid damaging the tank and ensuring fuel system integrity.

Relocating the Fuel Tank

Another option is to relocate the fuel tank to a different position, such as behind the rear seat or under the body of the Jeep. This approach can provide the necessary clearance for a wheelbase stretch without modifying the tank itself. However, it may introduce other considerations, such as noise, fuel smell, and safety concerns, especially if young children are riding in the vehicle.

Custom Fabrication

Custom fabricating a fuel tank is another possibility, which can be a more cost-effective alternative to aftermarket options. This typically involves welding and shaping steel or aluminium to create a unique fuel tank that fits the specific requirements of the Jeep TJ and the desired wheelbase stretch.

In conclusion, there are several ways to achieve a fuel tank stretch on a Jeep TJ, each with varying levels of complexity and cost. It is important to carefully consider the available options and select the one that best aligns with the desired stretch, budget, and intended use of the vehicle.

Jeep TJ gas tank capacity

The Jeep TJ Wrangler has a listed fuel tank capacity of 19 gallons, though some models have a 15-gallon tank. However, some owners have reported that they can only fill their tanks with 14-15 gallons of fuel when the gauge shows empty. This discrepancy may be due to the shape of the tank or the placement of the fuel gauge sensor.

There are also aftermarket gas tanks available for the Jeep TJ that offer larger fuel capacities, such as 20 or even 24.5 gallons. These replacement tanks are designed to fit in the stock location without requiring any modifications to the vehicle and provide increased fuel capacity for longer trips or improved fuel efficiency.

It is worth noting that the fuel gauge on the Jeep TJ is known to be inaccurate, with the low fuel warning light often coming on when there are still several gallons of fuel left in the tank. Some owners have reported driving up to 60 miles after the light comes on before refuelling. Therefore, it is recommended to fill up the tank before the light comes on to avoid running out of fuel.

Frequently asked questions