You can easily modify your stock Jeep Wrangler or Jeep Cherokee gas tank to hold 20 gallons if you only have a 15 gallon tank. Daimler Chrysler only made one tank for the Jeep YJ and Cherokee (87-95). So, if you didn't buy the 20 gallon tank option, the vent hose in the tank was extended so that you could only fill 15 gallons into the tank before it forced the pump to shut off.
It was a great way for them to save money, and I am glad they didn't make 2 tanks, because I now have a 20 gallon tank.
The modification is very, very simple. I am going to give instructions for doing this on a Jeep Wrangler, but you can use about the same steps to do it on a Jeep Cherokee. I will not give detailed instructions as the mechanically inclined can pick up on this. It's pretty simple, so use your head.
Our target today is the smaller vent tube going from your gas cap to your tank. You can drop the tank, or you can leave the tank in place. Since you are changing the capacity of your tank, you might want to drop it (empty all the gas first) and lower the fuel sending unit one notch (to correct your gas gauge).
I don't care how you get there, but remove the smaller vent tube from your gas tank's filler neck (after de-presurizing your fuel system). One you have it removed, you will see a smaller tube inside there. Pull this tube out using pliers. It's about 10" long and extends into your gas tank. Remove this tube and cut it down to about 2 1/2". After cutting it down, reinsert it into the tank and bolt everything back up...
You now have a 20 gallon tank!
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