My new Jeep had a little fuel problem...I could only pump in 11 gallons of gas at the most. That left me with only 150-mile range. Not cool, Dave. Every time I crawled under the Jeep to work on something I just stared at the tank confused at how such a big tank could hold so little fuel.
Well, last week I could take it no more. I yanked down the tank and had a look inside. Turns out the vent tube that allows flush-back to shut off the gas pump turned down inside the tank so that the opening was only halfway up. That means I could only fill half the tank. Even worse; it was designed that way! I know because the fuel level sender was maxed out half way up!
I cut the vent line and reinstalled it pointing up with some 1/2-inch fuel line and hose clamps I had in my toolbox.
Today I pulled the fuel pump and extended the fuel level sender float arm. I cut the aluminum arm and crimped in about 6 inches of steel vacuum line, which allowed the float to reach close to the top of the tank about the time it hit the upper stop.
It worked out great! I increased my usable fuel load from 11 gallons to 24.5 gallons, increased my range to 350 miles and made my fuel gauge accurate all without spending a penny!