Gas tank differences

Hi all - so we got a 2004 4x4 regular cab with the 2.7L that had a rusted out rear frame we built a new one and have the welding done and no are looking for the correct fuel tank - it seems there are different tanks listed for cab length, drive type and engine size are they really all different? we will be building a new tank mount anyway but are planning to reuse all the tank stuff

 

There actually were a bunch of different fuel tanks used throughout the production of 1st gens. I can't tell you exactly what's interchangeable, but I can tell you about some of the differences I've observed.

The fuel/vent line and filler neck interfaces changed over the years. I posted some comparison photos recently in another thread, quoted here:

The way tanks are mounted varies between cab styles. Regular cabs use two straps to support the tank, with the skid bolted to the rear strap and a front support arm that extends off the frame. Extended cab trucks have a single strap at the rear of the tank, with the front of the tank and the skid bolted directly to a frame crossmember. I'm not sure how double cabs are mounted. I'm also unsure if the tanks themselves are different or if it's just the mounting style that changed. The skid plates are different depending on the mounting style.

According to the Toyota manuals, 5-lug trucks got ~15 gallon tanks and 6-lug trucks got ~18 gallons. I think tanks are interchangeable, but you need to have the correct strap(s) for your tank (longer strap(s) for the longer tank).

Anecdotally, I've never put more than 15 gallons in my regular cab 6-lug even when running it down to E on the gauge. I'm not sure if that means I have a smaller tank (according to the manual it should be 18), or if it just means my gauge is misleading (it's normal for vehicles to have some "reserve" after hitting empty but 3 gallons seems like a lot).

 

Three gallons is typical. Some larger tanks (30-40 gallons) will have closer to 5 gallons left in the tank when you get to E. It's still not a good idea to keep driving once you hit E. When driving up, or down inclines what little gas is left moves to one end of the tank and cannot get to the engine. Same thing as running out of gas.

 

Indeed, my Tundra has the 38 gallon tank and reads empty with a full 8 gallons left in it. I only know that because I bought it that way, it's never been driven that low since

 

Fuel Cell Yo!

unless Fab work/emissions not your thing

I would investigate old school fuel tank refurbished shops. (Usually rural bc farmers are primary customers)
Had 70 Suzuki 120 tank refurbished
They sprayed coating inside too

this of course if your tank is totally rusted through

 

My 2001 extra cab manual 4wd 3.4 has the ~18 gal tank. I think it's like 17.2 gal. Hope this helps.

 

some good info & pics here too:

https://www.tacomaworld.com/threads/first-gen-fuel-tank-interchangeability.636772/