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UPDATE: You can now read about this conversion over at the Wrangler YJ web site.

    4. Remove the inner plastic fuel vent neck liner.

Inside the neck of the fuel vent hose, you can see a tube which lines the inside. This liner tube is made of hard plastic. It’s about 9.75" long and reaches about 7" into the tank. Gas can not be filled beyond the bottom of this tube. Shortening it will increase the volume of gas that will fit into the tank.

To remove it, you will need to pry it away from the sides with a small screwdriver and grab it with any small tool that offers a STRONG grip. I recommend a needle-nose vise grip because this tube is crammed in there TIGHT. In fact, removing this tube was the hardest task on this project. Some people removed this tube in sections by pulling out 3", then cutting it off, and pulling another 3" until the tube was completely removed.

NOTE: After the liner tube is fully removed, you must have at least one piece of it that is 3" long to be reinserted.

  5. Cut a 2.5" section from the liner tube.

The fuel vent neck on the tank must have a section of the liner tube pressed back inside to maintain pressure applied when tightening the hose clamp (during re-assembly). I have no idea why this is, but since someone advised to do so, I didn't argue.

Cut a 2.25"-2.5" section and fit it back into the fill vent neck. You’ll need a hammer or something heavy to pound it in.

NOTE: I was forewarned not to use a metal hammer should I be unlucky enough to strike any steel parts on the vehicle and cause a spark near all the gas fumes. When pounding the liner tube back in place, I left about 0.125" protrude beyond the fill vent neck in case I would have to pull it out again for any reason in the future.

 6. Reassemble everything in the reverse order.

Use the hose clamp to attach the fill vent hose to the fill vent neck, four rivets to reattach the plastic cover on the rear panel, and five lug nuts to mount the removed wheel.

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