I'm sure this has been posted about before so link me if it has...
My Issue(s) is this. My gas gauge will read full on a hill on a full tank. but on level ground its closer to 3/4. When the light comes on and I go get gas it only takes about 12-13 gallons to stop filling. And a lot of gas will overflow out of the neck whilst filling. I know I have the 20 gal. tank. the tank is really straight no dents or nothing like that. ive tried multiple floats to remedy this but no to avail. HELP?

 

When I get the light, I can typically only get 15 gallons or so in it, so there is a good 5 gallon reserve. Most XJs are notoriously hard to fill up. If you just stop at the click, you're missing 1 to 2 gallons. Once it clicks at the pump, I keep filling very slowly until I can hear it reaching towards the top. It's the only way I've found to do it.

 

Well I guess the reserve and light I can handle not a super big thing. but the gass spilling everytime I fill? any known fixes for that?

 

Cherokees can have 20 gallon or 15 gallon tanks. Here's the dirty little secret - the tanks are the same. The filler neck is different. Yep, they made money by selling people a bigger tank as an option, but they only produced one tank. The filler neck on the "15 gallon" tank is constructed so that it won't allow the tank to fill completely.

Get yourself a 20 gallon filler assembly and you'll probably solve all of your problems.

 

A 20L gallon jerry can won't even make the light come off from a literally empty 75L tank.

What's this about gas pouring out of the neck while filling? Are you overfilling it or is this all the time?

 

no its an all the time thing.

 

Yikes! What did you find when you crawler underneath and inspected the filler neck?

 

Not sure what you mean by finding with the filler neck. this past weekend I was on a road trip in the Colorado Rockies and didn't have any spillage issues not sure if that was due to the altitude or the fact I was trying to run the tank down as far as possible. any one successfully put a newer style tank and pump in their rigs? my other jeepis a 98 and we typically get around 300 miles on a tank where my 90 gets just under 200. both have th 20 gal tank

 

The two hoses that run between the gas cap and the tank. Loose clamp, debris, rotten hose, rotten metal at the cap side, and so on. Occasionally still hidden behind a little metal panel between the quarter panel and frame rail.