"...I'd have to get a lot more than another 5 gal capacity to make it worth swapping tanks."
The main reason I put the YJ tank into the Montero was that the stock tank was smashed in so bad that it only held about 12 useable gallons. The factory replacement tank was very expensive, and would soon be as badly smashed as the old one. That and I had the 20 gallon YJ tank already. Installing the larger tank meant one less can inside the truck, He carries a water can inside where he used to carry the extra gas can.
Further info on the YJ tank installation:
A '96 ZJ fuel sender fits onto the YJ sending unit module, along with a small resistor to match the ohms, and the Montero gauge works perfectly. Later, If we end up swapping in a turbo or EFI motor, the YJ pump module will supply the pressure needed. For the fuel filler hoses, I used some clear Vinyl tubing with some PCV pipe adapters. So far they have held up for over ten years, and they pass the CA EVAP leak tests done during CA smog checks.
PCV hose and PCV pipe fitting adapter and the tank filler vent hose connections (Yes the stock hose is about to go, but it still passes the CA EVAP leak tests!)
![[Linked Image]](http://i551.photobucket.com/albums/ii475/MartySoCal/IMG_4723.jpg)
The reinforced Vinyl filler hose connections to the YJ tank, stock Montero splash shield is still in place:
![[Linked Image]](http://i551.photobucket.com/albums/ii475/MartySoCal/IMG_4725.jpg)
![[Linked Image]](http://i551.photobucket.com/albums/ii475/MartySoCal/IMG_4720.jpg)
Sending unit connection, inside the wiring sleeve is a resistor to match the ZJ sender unit to the ohms of the stock sender unit, the gauge reads very accurately!
![[Linked Image]](http://i551.photobucket.com/albums/ii475/MartySoCal/IMG_4722.jpg)
If I had to make the skid plate all over again, I would probably make a completely new tank, eliminating some of the corners and the angle that the YJ tank had and get about 25 useable gallons inside the tank. A 28 gallon "Aero" replacement tank for the YJ may fit about as well as the tank setup I made up, or a completely new tank could be made if you had the fab skills.