07-14 38 Gallon Tank swap install thread

So I've run into an issue. When I got the 26 gallon tank out, I noticed that the 38 gallon has a 3rd line on the pump and the Barb is snapped. I also noticed the electrical connection is completely different. Anybody else run into this? I figured it would be a direct swap... Any help would be appreciated. I'm dead in the water at this point.

 

The pump with broken fittings is a flex fuel pump. Aren't you just swapping your pump into the larger tank?

 

I'm guessing that's what I have to do now. I figured I didn't have to and could use the one that's on the 38. Will I need a new pump gasket? I didn't anticipate this and didn't order one.

 

The gasket is just a rubber o-ring (If I recall correctly) The biggest thing to be careful with is the locking ring. But luckily you have 2. and probably have 2 gaskets too. There is a little tab on the fuel pump that breaks off easily (per another member) so don't rotate the pump while spinning the ring.

 

Got it. Thanks! Here we go...

 

Ok. Ring is off. No tabs broken. Pump stayed put. Gasket looks good. On to the 38...

 

Got it moved over. The only issue was where the tab is on the 38. It's in a different spot, about 90 degrees to the right. When I went to line the pump up to it, it wouldn't compress as easily and I had to persuade it slightly with a mallet. Then it compressed completely and I was able to screw the ring on fine. When I looked at both pumps side by side, the bottoms are shaped differently. Not sure if that has anything to do with it...

 

I wonder if that is just because it's a flex fuel sending unit on the used pump and that is why the bottom is shaped differently?

 

That's my guess. So I finally finished. What a PITA!! Issue now is the truck won't run. I disconnected the battery to reset everything and put 10 gallon of fresh gas in and it just cranks. Anything else I need to do?

 

I would of just brought 2 five gallon jugs on a long trip.

 

I can bring up to four if I need to

 

Do you hear the fuel pump running when you just turn the key on? - That is about my only guess to try...

 

Should I be able to hear it from the driver's seat?

 

i really want to do this but my wife usually needs to stop and pee every 100 miles, so i am stopping anyway.

 

I don't know that. I would think in a quiet area with nothing else on the truck you should hear it "hum" until pressure is obtained.

 

Did you try starting it right away?

what I did was, I cycled the ignition a few times before trying to starting it.

 

I don't believe this is how the toyota fuel system works. IIRC, the pump will not turn on simply because the key is in the ON position. It will only turn on when the engine is running. If I put my key in the ON position, I hear no pump, yet my truck still starts and runs.

 

I cycled it 10 times and still nothing. I do hear a slight hum underneath when the key is on.

 

I believe the truck starts and runs right away is the fuel line stays primed. I say that because when i disconnected the lines to drop the 26 gal, had to have a container to catch the fuel coming out from the lines.

@WFD473 I would double check the connections and make sure everything is tight. After installing the 38 gal, i turned it to the on position and let it sit for a minute. Then started it and it cranked for about 10-15 times before it fired up.

 

Ok. That's what I was thinking. Someone mentioned this some time ago when someone was trying to diagnose a fueling issue. The person with the problem went straight to the fuel pump because he wasn't hearing it with the key on and engine off. Someone else jumped in and said that the fuel pump won't turn on in that condition.

 

You have to engage the start signal then you will hear the pump. Just a slight click. Some cars , mostly older, can just be on, and you hear the pump for a few seconds as well.

 

Replaced the parking brake lines and bled the system yesterday. Planning on getting the crossmember in place today and installing the tank and TRD exhaust tomorrow.

 

Did you ever get your truck started?

 

I'm getting ready to install my crossmember. For people who have completed the installation, would this idea be any easier or not?
It wouldn't take much to cut/grind the welds attaching the crossmember bracket that goes to the frame on the passenger side from the crossmember itself and separate the two pieces. Then you could get the crossmember into the frame on the drivers side without trying to jam the crossmember between the frame rails in one piece. Once in place the passenger side bracket can be put in place, the crossmember can be slid back onto it and rewelded. Does this make sense and would it be any easier or just making more work for myself?

 

It's a good idea and maybe I would have tried it if I knew how to weld.

Might be similar as the welds are sizable. You might still have to do some trimming as the bracket itself is slightly large to fit in the frame unless you're able to wiggle it in once the welds are cut. If you were local I'd swap you cross members or help you with yours. I just finished mine and sitting ready to bolt to the frame. Once you trim it once, it's easy.

 

Sorry all for the delay in an update. So on Thursday after it wouldn't start, I had a buddy come by to take a look and we tested everything electrically from the battery and fuses/relays all the way to the fuel pump. Everything checked out ok. While the tank was still on the ground and fuel lines connected, we got it fired up, but it ran extremely rough and the check engine light was blinking. It was late, so we left it that way and I tried starting it in the morning. Again, it started, but ran rough. The next day I re-notched the driver's side so I would be happy with how the fuel lines and parking brake were sitting and connected everything and strapped the tank back in. Tried starting it and it just cranked and nothing. I tried priming it multiple times and nothing. At this point I was so frustrated (and I had dropped the tank like 4 times), that I called the shop that I have dealt with before and had it towed there. On Monday they asked if the electrical plug going into the fuel pump had a loose wire before, and I remembered that the blue wire had pulled out of the plug while we were moving the tank around but had put it back. They said that it was still loose and ordered/replaced it yesterday. I called in the afternoon yesterday to see how it was going and they said that after they replaced the plug and strapped the tank back in, it still wouldn't start. So they ran a fuel sample and it came back as being half fuel and half water! They drained it and added fresh fuel and it fired right up and ran great. My guess is that when the tank sat at the junk yard, water must have gotten in the tank through the fill neck over time. When I picked it up, what I thought was just gas in there apparently wasn't. Lesson learned. Sorry for the drawn-out story. Would I do it again? Hard to say at this point. I'll be happy that I did it when camper towing season starts in a couple weeks. If anybody has any questions, fire away. And thanks everyone for all your help throughout this.

 

probably some nice E85 glad you got your truck running!

 

Thank you sir! And good call, the tank was from a flex fuel truck. Who knows? Just glad I got my baby back

 

ThNks for the follow up and glad you got it running. Yeah. That was pretty risky using a unknown tank with any “fuel” inside. I would have definitely emptied all liquid but I am also worried about trash/debris inside these if I get one from a junkyard.