Jump to content


96 350 rear 19 gal fuel tank to 38 gal???

Rear fuel tank swap

1 reply to this topic

#1 964605crew


    F-Series Newbie

  • Members
  • 1 posts
  • Favorite F-Series Year?:1996

Posted 27 June 2015 - 02:48 PM

Looking to change fuel tank behind axle from 19 to larger is that possible and where are parts available from????

#2 miesk5


    F-Series Maniac

  • Moderators
  • PipPipPipPipPip
  • 145 posts
  • Gender:Male
  • Interests:Broncos, beach runs, surf fishing
  • Favorite F-Series Year?:1996

Posted 04 July 2015 - 05:10 AM

yo 96,

Look at conversion @ http://www.rosewoodd...llonOBStank.htm

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

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


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:

Lower ground wire attachment at the fuel level sensor bracket:

Upper ground wire attachment at the hanger tube bracket:

View of the completed assembly:

It hangs about 6" lower than the stock tank
I didn't modify modify the arm for the float . I figure once it starts moving off the full mark, I'll know I have about 18 gallons or so left.

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.
96 Bronco, E4OD, Man Xfer Case & Hubs
See my Big Bronco & F Series Technical & Parts LINKS site. Will need to clean up dead links & add many more new links some day. Thanks to Mr. Schwim! http://schwimserver5.com/?index=1128
Thanks to All Who Serve

Reply to this topic


0 user(s) are reading this topic

0 members, 0 guests, 0 anonymous users