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07-14 38 Gallon Tank swap install thread

Discussion in '2nd Gen Tundras (2007-2013)' started by papasmurf, Jun 11, 2018.

  1. Jun 11, 2018 at 6:35 PM
    #1
    papasmurf

    papasmurf [OP] Savage Fabrication

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    Hello everyone!!

    Just completed my 38 gal tank swap. And ill say this easy to do and 1 day install by yourself is doable.

    Ill start with a required parts list as well as a few parts that swap over and some suggestions along the way. Hope this clears everything up for everyone.

    Starting with parts needed

    PART NUMBER: 770010C120 38 Gal fuel tank
    PART NUMBER: 771690C010 Gasket- Fuel Suction , Fuel Pump Gasket ( you will want to install a new one when you put the old pump in the new tank)
    PART NUMBER: 7714408010 Retainer- Fuel Pump , Fuel Pump Retainer , Fuel Pump Assembly Retainer , Plate Retainer (Plastic Ring holds the fuel pump in , just good to put a new one on you may break your old one like i did , mine was old)
    PART NUMBER: 776010C120 Fuel Tank Strap (middle one)
    PART NUMBER: 776010C110 Fuel Tank Strap (front one)
    for the above two you dont need a rear one the 26 gal tank strap is the same)
    PART NUMBER: 833200C060 Fuel Sender Unit (Not needed But good to swap out on higher mileage vehicles since you are already inside the tank and pump
    PART NUMBER: 7765334050 Fuel Tank Assembly Pin
    PART NUMBER: 90119-A0249 BOLT, W/WASHER (Buy 3 to replace all the tank strap bolts)
    PART NUMBER: 77606-0C040 Protector Sub-Assy, Fuel Tank, NO.1 (Skid for tank, you can opt out and buy aftermarket skid)
    PART NUMBER: 510380C040 Member Sub-Assy, Fuel Tank Support

    Optional parts :
    PART NUMBER: 77697-0C050 Insulator, Fuel Tank Heat, NO.1
    PART NUMBER: 77697-0C060 Insulator, Fuel Tank Heat, No.2
    (heat shields, I didnt bother with them..)

    Parts you will reuse
    Fuel pump and assembly
    filler hose and evap connections
    fuel return and fuel supply line (be careful not to swap which hose goes where on both the pump and the truck, they have different size connections for the hard lines but on the pump its easy to get them backward.

    Ok now for pics and info

    To start here are some tips -
    When you drop the tank (try to be as close to E as possible.. otherwise it will be heavy and full of gas)
    When you pull the fuel pump there will be a quart or two of gas in the pump housing be careful as you will most likely spill some.. have rags handy
    use jack stands and a jack to power the tank in steps so you dont break any connections
    The retaining ring for the pump is tight and has 4 little plastic stops that prevent the cap from walking off they are a pain but every 1/4 turn you will have to depress the little tab to keep turning it off.


    Here is a side by side


    OK here is the parts pic you can compare with part #'s
    And the install pics
    You have to notch the cross member to get it in between the frame it will make sense once you notch it.

    Then you need to either drill and bolt the cross member i chose to just grind and weld the holes.. i used big clamps to hold it in place...its faster and easier if you have a welder than drilling, but not everyone has that option.. (BTW drilling the frame rails takes time, lube and a good drill and bit.. go slow it takes time)

    To get proper location i mocked the tank up with the front new cross member just in place and the used the rear and mid straps to strap the tank in place then marked the proper location of the new cross member .. then clamped it in place and pulled the tank back down and then welding it in



    Honestly yes this is costly, but worth it for a few reasons... one because 38 gal's, two Transfer flow (TF) not available in Cali, the TF tank is heavy (like 120lbs) and stock plastic 38 gal tank is less than half the weight (approx 40+ lbs), the TF tank sits below the frame while this stock tank doesn't, and lastly everything is Toyota parts so you get Toyota quality.

    So its all pretty straight forward. Let me know if anyone has questions, Always here to help.

    Thanks,
    Bruce
     
  2. Jun 11, 2018 at 6:53 PM
    #2
    tundrathr0w

    tundrathr0w New Member

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    Thanks for putting this together!!

    Where did you get the parts? Online? Some dealership?

    Did the gas gauge and the DTE calculation know that you swapped to 38 gallon, and remain accurate?
     
    Rica25, Rex Kramer and papasmurf [OP] like this.
  3. Jun 11, 2018 at 6:54 PM
    #3
    tundrathr0w

    tundrathr0w New Member

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    Do you know if this would work on 3rd gen Tundras? I have a 2018.
     
    Rica25 likes this.
  4. Jun 11, 2018 at 7:31 PM
    #4
    papasmurf

    papasmurf [OP] Savage Fabrication

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    I got all of my parts through my Toyota dealer, ive made friends with the parts guy over the years and he gives me his cost or matches online prices from legit Toyota parts retailers.

    The gas gauge works as it should and shows proper levels... and the DTE on my truck is screwy my buttons are broken I need a new info button thing to get it to work, but everyone i know who has done this says its accurate after a few drives and fill ups it re learns.
     
    Mountun Goat, Rica25, trayday and 2 others like this.
  5. Jun 11, 2018 at 7:32 PM
    #5
    papasmurf

    papasmurf [OP] Savage Fabrication

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    No reason why it shouldnt. I would say absolutely yes it should but havent tried it.
     
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  6. Jun 12, 2018 at 2:33 AM
    #6
    Bo-Hunter

    Bo-Hunter I like fast

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    Thank You Bruce great info
     
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  7. Jun 12, 2018 at 4:23 AM
    #7
    TXRailRoadBandit73

    TXRailRoadBandit73 RUNNIN' WITH THE DEVIL N MY TÜNDRA CRÜE

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  8. Jun 12, 2018 at 4:26 AM
    #8
    TXRailRoadBandit73

    TXRailRoadBandit73 RUNNIN' WITH THE DEVIL N MY TÜNDRA CRÜE

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    Great write up! Would like to do
     
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  9. Jun 12, 2018 at 5:16 AM
    #9
    mlucas555

    mlucas555 New Member

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    Still rocking the stock height.
    Thanks for the write up! I need to look into this, as the 26 gallon tank sucks while traveling.
     
  10. Jun 12, 2018 at 5:55 AM
    #10
    Harlan

    Harlan New Member

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    Thanks for the info. I've been thinking about replacing mine. 26 gallons is fine but I get nervous when low fuel indicator comes on though I know I have 6 gallons (or about 85 miles) left. In addition I can wait longer to find better fuel prices which can vary in California by 20-30cents/gallon.
     
  11. Jun 12, 2018 at 6:20 AM
    #11
    gosolo

    gosolo “The .com stands for communist”, Dale Gribble

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    2"CB shackles, bushings and 1 shim, lockerdown console vault, rear folding seat back mod, snugtop shell with opening side windows, 46g fuel tank, SDHQ sliders and hidden winch, Decked Drawers, Icon leaf spring packs and got rid of the interior chrome
    @papasmurf
    Great job, writing this up and good pictures!
    Would you mind saying what the total cost is? I have installed the transfer flow, but the additional weight is certainly significant.
     
    4x4_Angel and papasmurf [OP] like this.
  12. Jun 12, 2018 at 7:11 AM
    #12
    dcsleeper408

    dcsleeper408 BASTRDS

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    Very Nice!! Appreciate the detailed write+part #'s
    Been banking on a used one to pop up locally.
    What skid you gonna go with?
     
    papasmurf [OP] likes this.
  13. Jun 12, 2018 at 7:51 AM
    #13
    papasmurf

    papasmurf [OP] Savage Fabrication

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    Ok so total cost..

    Tank was 1000$, cross member and associated parts like another 4-500 and I bought the factory skid but decided against it so I’ll be doing the PP or RCI haven’t ordered yet... still weighing my options

    But I think I’m 1800$ all in on parts but I ordered some stuff that wasn’t needed or I’m going to return

    I think 14-1500$ should do it on parts
     
  14. Jun 12, 2018 at 7:52 AM
    #14
    dcsleeper408

    dcsleeper408 BASTRDS

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    CA legal. is the biggest plus side.
     
  15. Jun 12, 2018 at 8:04 AM
    #15
    4x4_Angel

    4x4_Angel Perfectly Imperfect Tomboy....TTC #132

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    Great write up and pics! Now i need to learn to weld.....
     
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  16. Jun 12, 2018 at 8:31 AM
    #16
    PRO BLANCO

    PRO BLANCO Dirt biking & fishing

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    Damn!! Great job Bruce! I need this!!
     
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  17. Jun 12, 2018 at 8:39 AM
    #17
    Jerry311SD

    Jerry311SD New Member

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    I'm Suprised, everything is illegal here. LOL


    OP Nice write up.!
     
  18. Jun 12, 2018 at 8:45 AM
    #18
    osidepunker

    osidepunker OsidePunker

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    Damn dude that one helluva write up! Awesome :thumbsup: We'll do mine next year maybe

    MODS THIS NEEDS TO BE A STICKY
     
  19. Jun 12, 2018 at 8:52 AM
    #19
    big_jarv

    big_jarv New Member

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    Great write up. That 26 gallon tank looks dinky next to the 38.

    Also didn’t know the tf was illegal in CA.
     
  20. Jun 12, 2018 at 8:53 AM
    #20
    osidepunker

    osidepunker OsidePunker

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    TF tank is not CARB approved
     
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  21. Jun 12, 2018 at 9:58 AM
    #21
    big_jarv

    big_jarv New Member

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    Ah makes sense.
     
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  22. Jun 12, 2018 at 10:28 AM
    #22
    MacCTD

    MacCTD New Member

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  23. Jun 12, 2018 at 8:49 PM
    #23
    papasmurf

    papasmurf [OP] Savage Fabrication

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    Thanks everyone!! I try to do useful posts and good write ups... wait till you see my camburg LT rear build write up and of course check my build thread for other write ups
     
  24. Jun 12, 2018 at 9:13 PM
    #24
    dcsleeper408

    dcsleeper408 BASTRDS

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    U doing the camburg bed cage?
     
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  25. Jun 12, 2018 at 9:24 PM
    #25
    papasmurf

    papasmurf [OP] Savage Fabrication

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    Yup!

    Camburg bed cage
    Camburg LT SUA bump mounts
    Camburg SUA parts
    Deaver i96xhd custom leafs
    King 16” 3.0 triple bypasses
    king 2.0 bumps

    All the parts are sitting in my garage ready to go in... just need the time to do it!
     
  26. Jun 12, 2018 at 10:31 PM
    #26
    dcsleeper408

    dcsleeper408 BASTRDS

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    Hell yeah! That’s a solid setup!
    What’s the weight rating on the xhd packs?
     
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  27. Jun 12, 2018 at 10:39 PM
    #27
    n2deep

    n2deep Pavement Princess

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    Not enough. Haha. It's like 500lbs
     
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  28. Jun 12, 2018 at 10:50 PM
    #28
    papasmurf

    papasmurf [OP] Savage Fabrication

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    It’s 700 I think it was @osidepunker most recent pack before he went to a wider leaf... based on how much I weigh and he weighs they should work great for me. I’m 700lbs lighter than him fully loaded. But we shall see
     
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  29. Jun 13, 2018 at 4:16 AM
    #29
    osidepunker

    osidepunker OsidePunker

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    It's not an XHD pack. Its full custom. But Jeff just eyeballed it, he wasn't working with an actual weight like the last packs I had built. Your packs were built from scratch out of thicker leaf material than the XHD packs
     
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  30. Jun 13, 2018 at 6:39 AM
    #30
    papasmurf

    papasmurf [OP] Savage Fabrication

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    Thank you for the clarification and now I know too lol!
     
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