26 to 36 gallon fuel tank swap

[rustyrider]

Will a 36 gallon 2015 tank's fuel pump work? Or will it need to be replaced?

i don't know for sure, but the later coyote motors have direct injection along with port injection. i would suggest searching out part numbers at an official ford parts dealer to see if they're the same.

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[rdatkins]

Rustyrider did you eventually get the distance to empty calculation sorted out correctly?

 

[digitaltrucker]

i don't know for sure, but the later coyote motors have direct injection along with port injection. i would suggest searching out part numbers at an official ford parts dealer to see if they're the same.

Thanks not sure I would want to do this witha 10 year old pump anyway. Also is there only one Forscan change in the IPC?

 

[the_swd]

if you buy a junkyard gas tank, it will come with the heat shield, more than likely. Someone would have to go to a lot of trouble to separate the heat shield from the tank. I did this several years ago now and I don't remember getting the straps with the replacement gas tank. The new tank is a little deeper than the original, however it gains most of its capacity because it's longer. I paid a shop to do the actual tank swap, and I was never notified there was a problem with the straps being too short. I recently tossed the old gas tank and there were no straps with it so I must have reused the originals. I apologize for not giving a better more concrete answer.

I also just recently traded the truck in for an f250, so i don't have it sitting in the driveway to go out and take a look at for reference.

I'm curious, how much did you pay for the swap?

 

[rustyrider]

I'm curious, how much did you pay for the swap?

i had about $750 in it, including buying all the parts and paying a shop to do the actual work.

it's more than buying one off the lot with a 36 gallon tank, but i couldn't find one when i purchased the truck.

 

[digitaltrucker]

SO I like to keep a fluid relationship with my service dealer. I reached out to my service guy for 2 projects.

First to install the illuminated keyless entry on my wifes new 25 Explorer. I have the part. At the time, if you had ordered at the time of build, it was a dealer listed install item at $455. I paid about $125 for the part thinking I could install, but it does not seem folks have been successful using Forscan to activate, but using FDRS (more expensive) they were. We did not order the car, it was on the lot and we flew to another city to buy and they could do this install, but could not get the part for a week. My service dealer wants $311 labor. Will most likely have to bite the bullet on this one and do it, unless I can find success with Forscan and or someone in my area knowledgeable and has a FDRS device.

Second project, I inquired about the 26 to 36 gallon tank swap. I asked for a full quote parts and all. He came back with no parts listed but stated the labor was $1.119.51.

So it looks like the tank swap will be done in the garage, when I do it.

 

[rdatkins]

My hold up, at this point, is it seems that there's no answer for getting the DTE adjusted for the larger tank. I think that might be more annoying than the frequent fill ups. I guess I could just ignore it but man, that would be annoying.

 

[rustyrider]

My hold up, at this point, is it seems that there's no answer for getting the DTE adjusted for the larger tank. I think that might be more annoying than the frequent fill ups. I guess I could just ignore it but man, that would be annoying.

a dealer willing to spend the time with the fdrs stuff could probably sort it out, however it probably wouldn't be cost effective to have them spend the time it takes to do it. it seems the issue with forscan is that the fuel levels and dte are originally controlled by the pcm. using forscan and pointing everything to the IPC is a work around that obviously only works marginally. I was happy with the results as it related to towing our camper and being able to go further between fill ups, but honestly, i probably wouldn't do it over again, because of the incorrect fuel level reading and the DTE.

i'm pretty much in the same situation now with my '24 f250. there is an aftermarket extended range tank available, but it's 2700$! So i've opted to buy a titan sidekick transfer tank and be happy with that. it will basically be for emergency use when towing in case we just plan poorly enough to be caught in between gas stations.

 

[digitaltrucker]

So as of this date, April 6, 2025, is it still that the DTE is still wrong, even when you use Forscan to change from a 26 to 36 gal?

 

[rustyrider]

So as of this date, April 6, 2025, is it still that the DTE is still wrong, even when you use Forscan to change from a 26 to 36 gal?

it's wrong on first fill up. i fooled with the numbers numerous times as the fuel level subsided to try to get it somewhat accurate as it neared empty. I was successful in that regard, however on first fill up, it will show 999 miles to empty and i can travel about 75 miles before that number changes. by the time it gets to a little less than half a tank, the dte apprears to be fairly close.

fwiw, i traded the truck in mid feb '25 for a f250, so i can't go into forscan and look at what the tank size numbers are, but my guess the gallons for the tank size is around 95. you also have to point the fuel level sender away from the pcm to the ipc, going from memory.

 

[digitaltrucker]

it's wrong on first fill up. i fooled with the numbers numerous times as the fuel level subsided to try to get it somewhat accurate as it neared empty. I was successful in that regard, however on first fill up, it will show 999 miles to empty and i can travel about 75 miles before that number changes. by the time it gets to a little less than half a tank, the dte apprears to be fairly close.

fwiw, i traded the truck in mid feb '25 for a f250, so i can't go into forscan and look at what the tank size numbers are, but my guess the gallons for the tank size is around 95. you also have to point the fuel level sender away from the pcm to the ipc, going from memory.

Thanks, interesting why would you need to tell the system that there are 95 gallons instead of 36?

 

[rustyrider]

Thanks, interesting why would you need to tell the system that there are 95 gallons instead of 36?

i don't know the reason, but putting 36 in doesn't work. it decreases the dte substantially.

 

[mbernstein1018]

I’m doing the swap next week. Do all of the vapor lines reach where they need to? the part numbers for the extended tank and standard tank are different but don’t appear to have any significant differences.

 

[rustyrider]

I’m doing the swap next week. Do all of the vapor lines reach where they need to? the part numbers for the extended tank and standard tank are different but don’t appear to have any significant differences.

i had a shop do the actual swap. the only part i bought beside the fuel pump was the tank itself. they didn't notify me that they had to modify or purchase anything else to complete the work. that's the best i can answer.

 

[Davv97]

When the gas tank gauge itself shows empty even after all of the forscan tweaks, does it constantly popup with warnings or chimes even though you may have a bunch of gas left in the tank? Or when the gauge hits empty is that actually pretty accurate even if the rate at which the gauge decreases isn't quite correct?

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