Fuel Tank Relocation (and new Rear Bumper design)

[2TH4IST]

Got the tank skid made! Came out awesome, lots and lots of cutting and grinding. And now it's beverage time! Added a front stiffner for more rigidness. Don't know the weight but it's heavy. I went 19" deep and 37.5" wide with around 3/8 clearance under the f150 tank sump bump thingy. Painted it the same color as the bumper. Tomorrow will be installing it, watching paint dry is boring. And upside down pics cuz why not?

 

[Team_Jake]

I wanted to give an update on the fuel tank sending unit brackets.

I received the brackets from the metal shop. The Toyota sending unit fits onto the bracket and mounts onto the Ford fuel pump assembly perfectly. When mounted, everything feels secure and looks like it all belongs together:

There are still a few things I need to do before everything is ready. Unfortunately, on Friday I am going to be leaving on a 3 week long road trip and won't be able to finish this project before then. I apologize for the delay, but I anticipate to have everything done and kits ready to ship by the last week of August.

 

[AssBurns]

I wanted to give an update on the fuel tank sending unit brackets.

I received the brackets from the metal shop. The Toyota sending unit fits onto the bracket and mounts onto the Ford fuel pump assembly perfectly. When mounted, everything feels secure and looks like it all belongs together:

There are still a few things I need to do before everything is ready. Unfortunately, on Friday I am going to be leaving on a 3 week long road trip and won't be able to finish this project before then. I apologize for the delay, but I anticipate to have everything done and kits ready to ship by the last week of August.

Now this is awesome!

 

[Bad Luck]

I wanted to give an update on the fuel tank sending unit brackets.

I received the brackets from the metal shop. The Toyota sending unit fits onto the bracket and mounts onto the Ford fuel pump assembly perfectly. When mounted, everything feels secure and looks like it all belongs together:

There are still a few things I need to do before everything is ready. Unfortunately, on Friday I am going to be leaving on a 3 week long road trip and won't be able to finish this project before then. I apologize for the delay, but I anticipate to have everything done and kits ready to ship by the last week of August.

Awesome design work and ingenuity! So with using the ford pump and the toyota level sensor/adapter, what modifications will you have to make to the ford tank?

 

[Team_Jake]

Awesome design work and ingenuity! So with using the ford pump and the toyota level sensor/adapter, what modifications will you have to make to the ford tank?

To the actual tank itself -- nothing. The Ford fuel pump / sending unit assembly is what will need modification. The old Ford sending unit will be removed from the fuel pump assembly and replaced with the Toyota sending unit and custom bracket. A hole will be drilled through the top plate / lid of the fuel pump assembly so that a new bulkhead connector can be installed which will run the wires to the Toyota sending unit.

And that's really it as far as mods go. There are a few more steps to get it all to work which I will detail at a later time.

And thank you for the compliment.

 

[rickashay]

There are still a few things I need to do before everything is ready. Unfortunately, on Friday I am going to be leaving on a 3 week long road trip and won't be able to finish this project before then. I apologize for the delay, but I anticipate to have everything done and kits ready to ship by the last week of August.

Stoked for this. Thanks for taking the time to make the Toyota stuff work.

 

[Bad Luck]

To the actual tank itself -- nothing. The Ford fuel pump / sending unit assembly is what will need modification. The old Ford sending unit will be removed from the fuel pump assembly and replaced with the Toyota sending unit and custom bracket. A hole will be drilled through the top plate / lid of the fuel pump assembly so that a new bulkhead connector can be installed which will run the wires to the Toyota sending unit.

And that's really it as far as mods go. There are a few more steps to get it all to work which I will detail at a later time.

And thank you for the compliment.

Looking forward to the rest of the details! I was under the impression that the tank needed to have components transferred from the toyota tank for evap/emissions stuff and to vent for filling.

 

[calebb]

Is there a major safety concern to be had with moving the tank behind the rear axle? It's common practice for automakers today to place the tank forward of the rear axle where it is more protected. In my reading I believe all vehicles produced today are forward of the axle. However, I know with another crossmember on the end of the frame, a steel bumper, and even a skid on the underside of the tank it is far more stout than factory.

Just want reassurance lol, I want to do this but have also read of the fiery horror stories online of rear mounted gas tanks. Any thoughts?

 

[rexassian]

Is there a major safety concern to be had with moving the tank behind the rear axle? It's common practice for automakers today to place the tank forward of the rear axle where it is more protected. In my reading I believe all vehicles produced today are forward of the axle. However, I know with another crossmember on the end of the frame, a steel bumper, and even a skid on the underside of the tank it is far more stout than factory.

Just want reassurance lol, I want to do this but have also read of the fiery horror stories online of rear mounted gas tanks. Any thoughts?

I think it's more for an easy place to put the spare than safety (IMHO). My suburban has an aux tank behind the axel in the same spot as we're talking about here. And of course Jeeps have had their tanks back there for forever as well.

 

[phattyduck]

Is there a major safety concern to be had with moving the tank behind the rear axle?

Ah, the Pinto. It wasn't just because the tank was behind the axle, there were MANY reasons together that caused the problem:

Basically, make sure the gas tank doesn't get punctured, and make sure you can get out of the vehicle if it does and you will be fine.

There are plenty of cars out there on the road with rear mounted tanks. As others have said, often the tank placement in the middle is because there is a good spot below the rear seat bottoms that is otherwise unused, or a spare in the rear (trucks/ladder frame SUVs) is more convienient.

That said, my Camry has a rear mount tank (Alltrac version only) - and Toyota did take extra care to keep any puncture sources away from the tank (even the rear diff mount has a special rounded spacer washer that is called "PROTECTOR, FUEL TANK, NO.2" to avoid tank punctures).

-Charlie

 

[2TH4IST]

I would defiantly put a skid on the tank when you do the swap. It doesn't hang below the bumper but when you get rear ended the car will go under the runner. I put a skid on mine and it was pretty easy. Eimkeith even provided the rear bumper bolt patter to make drilling easy a few posts back when I asked.

My skid is 45 pounds and covers 85% of the tank, if they hit you that hard then there are other things to worry about. Also remember, cars don't blow up like in the movies. Needless to say most tanks are located infront of the rear axle due to most cars being fwd. So there is a abundance of space. In my miata if I take a metal shield off I can touch the tank. Granted it's in the middle of the car, it is in the passenger compartment though.

Just do it, build a skid plate and enjoy the udderless clearance and better balance the runner will have but this is just the whiskey talking.

 

[Doc2012]

Stoked for this. Thanks for taking the time to make the Toyota stuff work.

Have you not read [MENTION=118207]midcoma[/MENTION]’s write up?

Extremely detailed, using the Toyota sending unit and pump.


Sent from my iPhone using Tapatalk

 

[VernySanders]

Have you not read [MENTION=118207]midcoma[/MENTION]’s write up?

Extremely detailed, using the Toyota sending unit and pump.


Sent from my iPhone using Tapatalk

I've got to read it. I need to relocate my tank before winter so I can focus on 4 link stuff

 

[Bad Luck]

Have you not read [MENTION=118207]midcoma[/MENTION]’s write up?

Extremely detailed, using the Toyota sending unit and pump.


Sent from my iPhone using Tapatalk

Midcoma's write up is great, but requires a lot of tank modifications that I would rather not do

 

[Team_Jake]

Getting close!

Tested (outside of the fuel tank) and everything works.

My last box of electrical parts is scheduled to arrive Friday, then I can finally start making the electrical harnesses. Look for an update early next week.

 

[Team_Jake]

New thread for the sending unit kit >>

F150 Fuel Tank + Toyota Sending Unit Kit

 

[pfeenstra]

Does anyone have a solution for the filler neck? I'm not really sure how to go about putting the filler in, and I would rather have it low-key since I live in CA, so that I don't fail smog.

 

[MN4runnerman]

Does anyone have a solution for the filler neck? I'm not really sure how to go about putting the filler in, and I would rather have it low-key since I live in CA, so that I don't fail smog.

I cut the OE filler tube just above where it bends so that it was straight then I used 2 90* fuel filler hoses to make the connection to the tank and the OE steel filler neck. In between the hoses I used a fuel filler coupler. Lots of companies make them. The hose I bought was gates brand I don’t remember the part number. Pretty sure the outer diameter was 2 1/4”. You’ll need nice hose clamps and the vent tube you’ll need to modify. I’ve had no leaks from it at all and I’be got maybe 5000 miles since I did this last spring. Also it’s easily hidden behind all the stock panels so they shouldn’t even be able to see it.

 

[sleepydad]

I cut the OE filler tube just above where it bends so that it was straight then I used 2 90* fuel filler hoses to make the connection to the tank and the OE steel filler neck. In between the hoses I used a fuel filler coupler. Lots of companies make them. The hose I bought was gates brand I don’t remember the part number. Pretty sure the outer diameter was 2 1/4”. You’ll need nice hose clamps and the vent tube you’ll need to modify. I’ve had no leaks from it at all and I’be got maybe 5000 miles since I did this last spring. Also it’s easily hidden behind all the stock panels so they shouldn’t even be able to see it.

I'm in the parts collection process of this project.... the bronco graveyard no longer has the upper straps.

what did you use? please advise?

 

[MN4runnerman]

I'm in the parts collection process of this project.... the bronco graveyard no longer has the upper straps.

what did you use? please advise?

I bought mine from the bronco graveyard can’t believe that aren’t carrying them anymore wtf. They were made in China anyways so I bet someone else has them. I found some dorman ones part # 578-026. They look exactly the same