Retrofitting the 33 gallon tank

[FestivalBro]

Mine came with a 26gal. I did the swap to a 33gal. My dad has identical truck as me and he got it stock with a 33gal. So I used his as a base to see how stuff was run as well.

My pics and info and how to are all over this thread earlier on. I haven’t followed it much as this thread is somewhat getting long and hard to follow now and since I’ve done it I don’t watch this thread as much now.

Where did you get the swap done?

 

[6of36]

. I did the swap to a 33gal. It's his second sentence.

 

[FestivalBro]

Does anyone know how to find the right parts for a VIN? 2022 ecodiesel with 26gal.

 

[cskindt]

Another project showed up today.

 

[JRD]

Has anyone gotten dealer prices for the swap recently? I’m going to call tomorrow but I’m assuming they are wildly out of control since they tried to charge over $800 for a remote start installation on my wife’s jeep.

Also, for those of you that have already swapped tanks. What is the difficulty level 1-10. By all account this only seems to take 2-3 hours.

 

[JRD]

Another project showed up today.

View attachment 166216

Let us know how it goes!

 

[JRD]

Here is my total cost of 26 to 33 tank swap with oem brand-new parts

part#	description	price
68408875AD	TANK-FUEL	$ 280.00
52030458AB	STRAP-FUEL TANK	$ 30.70
52029908AB	HOSE-PURGE	$ 56.90
52030443AB	BUNDLE-FUEL LINE	$ 74.45
6104717AA	NUT-HEXAGON FLANGE LOCK	$ 3.70
68307831AB	TUBE-VAPOR	$ 30.60
68418923AC	REINFORCE-FUEL TANK STRAP	$ 16.13
AlphaOBD		$ 50.00
2 X 2 X 1/4 A-36 Steel Angle	3rd strap support	$ 11.56
1/2 X 2 Hot Rolled A-36 Steel Flat	3rd strap support	$ 35.12
Steel bars shipping and tax		$ 33.32
TOTAL		$ 622.48

attached are images of 3rd strap fabricated support

could you use a nut and bolt instead of welding it?

 

[cskindt]

Let us know how it goes!

Will do!

 

[JRD]

Alright folks, here is what Ive gathered so far after looking at this tank and parts diagrams. Here is what I really think you all going to need. I will modify or update this later once I make the swap, but will be slightly different for me since I got a good bit of parts already.

Here are all the parts and costs I found for them that I believe you will need as the parts diagrams show them as different part numbers for 33gal tank vs 23/26gal.

---------------------
68408876AC - 33gal tank #1 on diagram (fuel tank) $411.60
68312139AB - Hose Vent #4 on diagram (fuel tank) $40.65
68312140AC - Hose Fuel Return #5 on diagram (fuel tank) $30.86
52030458AB - Strap Fuel Tank #8 on diagram (fuel tank) (Third strap needed in addition to the two existing from 26gal $20.07
06104717AA - Nut Flange Hex #9 on diagram (fuel tank) Need this for strap above $2.53

68307831AA - Tube Vapor for Crew Cabs #1 on diagram (hose fuel) (Mounted to drivers side frame rail) $20.76
52029908AB - Hose Purge #2 on diagram (hose fuel) or #3 on diagram (vent canister) (Cannot reuse 26gal one, too short) $31.35

52030443AB - Bundle Fuel Line #4 on diagram (vapor canister) $44.72
52029888AB - Canister Vapor #5 on diagram (vapor canister) Shows different part number from 23/26gal $103.53
52029909AC - Hose Filter to Canister #8 on diagram (vapor canister) Shows different part number from 23/26gal $13.57
---------------------

Thats 10 parts I see. The cost on all that is $720 or so before any tax or shipping. Probably will be easily over $800-850 if shipped with tax. Im attaching the diagrams as well as I reference them in the information above.

I know for me looking at my tank from the junkyard, Im going to need the 52029909AC since that didnt come with it, and will need the 68307831AA, this one I know I need cause that vapor line right now is against the drivers frame rail and its going to be too long and will need this part number to accommodate the quick disconnect fitting on it. Then I will pull my tank down and hopefully compare some parts to see if my list above holds water or not, but according to the diagrams, it seems like they are needed.

was this the final version of the 26 to 33 gal? i went through the entire thread but want to make sure i didnt overlook it somewhere

 

[cskindt]

was this the final version of the 26 to 33 gal? i went through the entire thread but want to make sure i didnt overlook it somewhere

You can spend much less on parts if you only buy the minimum parts necessary.
The tank price is much less now too. Your local dealer should be able to get it for at most, 275, without any discounts. It's going for around 190 online, but watch shipping fees.

 

[JRD]

You can spend much less on parts if you only buy the minimum parts necessary.
The tank price is much less now too. Your local dealer should be able to get it for at most, 275, without any discounts. It's going for around 190 online, but watch shipping fees.

That’s what really surprised me to be honest, I have the 26g so that saves me on the pumps. I found the tank for like $190 + $15 shipping. All in the parts were only like 5-600 bucks and with two small kids were going to be taking more road trips so that extra range would be nice.

You have the 26g stock as well right

 

[cskindt]

Yes, I have the 26g tank and a quad-cab.
I only bought 4 parts:
68408875AF - 33g gasoline tank
52030443AC - fuel line bundle
52029908AB - purge hose
57008588AA - vapor tube (might be specific to quad-cabs)

I plan on reusing everything else.

 

[cskindt]

I swapped out tanks tonight.
It took about an hour and a half by myself. It was a whole lot easier than pulling out the telematic module (unrelated to the fuel tank - it was another mod I did before the tank swap).

I only needed the four parts I listed above. Even the canister fit without any issues. It was pointed out in an earlier post that the white thing on the end that the hose connects to is oriented differently between the 26 and 33 gallon tanks. That is incorrect. In the photo that demonstrates this, the module is just twisted because that's how you remove it. Mine was the same as it is on the 33 gallon tank. The subtle shape difference is of no concern. The brackets on the tank hold the 26 gallon canister perfectly, without compromise.

I didn't use any 3rd bracket and don't intend to use one. I could hang off of the front of the 33 gallon tank and it doesn't move or flex. It's stout. Of course, that is only my opinion. If my truck had the provisional bracket for the strap, I'd install it. It doesn't, so I won't.

I set the fuel capacity to 125 liters with AlfaOBD, filled my tank with about 2.5 gallons from a jug, then went down to the gasoline station and filled it up. It took 30.7 gallons.

I did reuse the heat shield. It was under the truck when I took the pictures.

 

[JRD]

I swapped out tanks tonight.
It took about an hour and a half by myself. It was a whole lot easier than pulling out the telematic module.

I only needed the four parts I listed above. Even the canister fit without any issues. It was pointed out in an earlier post that the white thing on the end that the hose and connector plug into is oriented differently between the 26 and 33 gallon tanks. That is incorrect. In the photo that demonstrates this, the module is just twisted because that's how you remove it. Mine was the same as it is on the 33 gallon tank. The subtle shape difference is of no concern. The brackets on the tank hold the 26 gallon canister perfectly, without compromise.

I didn't use any 3rd bracket and don't intend to use one. I could hang off of the front of the 33 gallon tank and it doesn't move or flex. It's stout. Of course, that is only my opinion. If my truck had the provisional bracket for the strap, I'd install it. It doesn't, so I won't.

I set the fuel capacity to 125 liters with AlfaOBD, filled my tank with about 2.5 gallons from a jug, then went down to the gasoline station and filled it up. It took 30.7 gallons.

I did reuse the heat shield. It was under the truck when I took the pictures.

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your not a mechanic are you lol, i just want to make sure before i try to tackle this project

 

[cskindt]

your not a mechanic are you lol, i just want to make sure before i try to tackle this project

It's not my profession. I'm just a knowledgeable DIY'er with a background in mechanical/electrical/industrial controls.

It's not all that difficult to swap tanks. Just drive until your tank is almost empty. It's much lighter and easier to handle taking it out. AND - no matter how empty it is, there will always be gasoline vapors present! Do not work in an area with any ignition sources. Use a brass drift or punch to persuade the fuel pump lock ring. Steel tools can spark. Or at least use a fan to blow freah air across your work area - this will keep the local atmosphere below the lower explosive limit (LEL) and ignition can't occur.

 

[silver billet]

your not a mechanic are you lol, i just want to make sure before i try to tackle this project

Yeah no kidding lol. I think you should go next and post your results, then I'll feel a little more confident tackling it myself

 

[JRD]

Yeah no kidding lol. I think you should go next and post your results, then I'll feel a little more confident tackling it myself

Lol I know it, when I see all these people doing it saying it takes like 1-2 hours I’m like well I don’t see myself doing it that quickly. I’m sure I can get the tank out quickly but can I get it back in lol. But that said, there are a number of posts with pretty thorough instructions. I have so many things I want to do to my truck now I just need to decide what first

 

[jakev]

I am going to try to do the 23 to 33 gallon swap in my 2022 Bighorn just to confirm and for reference this is the list of parts and the cost. Hopefully I am not missing anything.. not sure if I need to get a prefab bracket or if the strap can mount to this underneath (see pic). Let me know what you guys think. Thanks!

Part #	Description	Cost
68408875AF	33 gallon fuel tank	184.5
68409160AE	fuel pump	465.43
52030458AB	3rd fuel tank strap	27.97
06104717AA	nut	2.61
52029888AD	vapor canister (EVAP)	168
52029909AC	hose from vapor canister to fresh air filter	18.53
52029908AB	hose from vapor canister to vapor tube	51.21
68307831AB	vapor tube	27.91
52030443AC	fuel line bundle	61.83
04721916AA	lock ring for fuel pump	12.74
52029964AD	skid plate	338.99
		1359.72

 

[cskindt]

I am going to try to do the 23 to 33 gallon swap in my 2022 Bighorn just to confirm and for reference this is the list of parts and the cost. Hopefully I am not missing anything.. not sure if I need to get a prefab bracket or if the strap can mount to this underneath (see pic). Let me know what you guys think. Thanks!

Part #	Description	Cost
68408875AF	33 gallon fuel tank	184.5
68409160AE	fuel pump	465.43
52030458AB	3rd fuel tank strap	27.97
06104717AA	nut	2.61
52029888AD	vapor canister (EVAP)	168
52029909AC	hose from vapor canister to fresh air filter	18.53
52029908AB	hose from vapor canister to vapor tube	51.21
68307831AB	vapor tube	27.91
52030443AC	fuel line bundle	61.83
04721916AA	lock ring for fuel pump	12.74
52029964AD	skid plate	338.99
		1359.72

That is not a bracket for the 3rd strap. If you need it, you'll have to improvise.

 

[barrak]

I am going to try to do the 23 to 33 gallon swap in my 2022 Bighorn just to confirm and for reference this is the list of parts and the cost. Hopefully I am not missing anything.. not sure if I need to get a prefab bracket or if the strap can mount to this underneath (see pic). Let me know what you guys think. Thanks!

Part #	Description	Cost
68408875AF	33 gallon fuel tank	184.5
68409160AE	fuel pump	465.43
52030458AB	3rd fuel tank strap	27.97
06104717AA	nut	2.61
52029888AD	vapor canister (EVAP)	168
52029909AC	hose from vapor canister to fresh air filter	18.53
52029908AB	hose from vapor canister to vapor tube	51.21
68307831AB	vapor tube	27.91
52030443AC	fuel line bundle	61.83
04721916AA	lock ring for fuel pump	12.74
52029964AD	skid plate	338.99
		1359.72

I thought one can reuse the existing fuel pump. That's a big expense.

I also thought a crossmember is required to install the fuel tank skid plate. Following is what I researched before I dismissed the fuel skid plate idea due to the compromised ground clearance:

68348386AB - Frame cross member
4x 06508646AA and 6x 06104416AA - hardware to install the cross member, 4 retainer nuts and 6 bolts