Sylvie Willis
The Wild Horses 23-gallon fuel tank is a popular upgrade for 66-77 Ford Broncos, offering almost double the fuel capacity of the original tank. Installation can be a challenging process, requiring several hours of work and a range of specialised tools and equipment. The process begins with running the existing tank down to a minimum of fuel, before removing the old spacers and power washing the area. The new tank must then be carefully manoeuvred into place, taking care not to damage the fuel connections. The supplied hardware, such as bolts, may need to be replaced with higher-quality alternatives. The installation process may also require additional steps, such as painting and undercoating, to ensure a durable and long-lasting upgrade.
| Characteristics | Values |
|---|---|
| Fuel Tank Capacity | 23 gallons/87 liters |
| Construction | 14 GA Stainless steel, tig welded |
| Adjustable | Fits 0-3 inch body lift |
| Fuel Injection Ready | High-pressure pump included |
| Protection | 3/16 inch thick form-fitting skid plate |
| Compatibility | 66-77 Ford Bronco |
| Installation Time | 3-20 hours |
| Installation Tips | Run the tank down to minimum fuel, powerwash/hose down the working area, remove old spacers, use a drinking buddy, be careful when jacking the tank into place |
| Common Issues | Fuel hose rupture, fuel starvation, vapor lock |
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What You'll Learn
Prepare the working area
Preparing the working area is crucial before installing the Wild Horses 23-gallon fuel tank. Here are the steps you should follow:
Firstly, ensure you have run the existing tank down to a minimum amount of fuel. With just a gallon or two remaining, it becomes easier to manage the removal of the old tank. This step should take about an hour, allowing you time to carefully remove the strap, old tank, and safely store the remaining fuel.
Next, it is important to clean the area. Powerwash or hose down the space under the bed where the old tank was located. This will help to reduce the amount of dust and debris that can get in your eyes or interfere with the installation process.
After cleaning, proceed to remove the old spacers that are in place to prevent the previous tank from touching the bed. This step is crucial to prepare for the installation of the new Wild Horses fuel tank.
Now, it is a good idea to invite a friend to assist you. Installing the new fuel tank is not an easy task to manage alone, and having an extra pair of hands can be extremely helpful. It is also recommended to have a drinking buddy to avoid any potential arguments with your partner or spouse during the installation process!
Finally, before beginning the installation, exercise caution. The Wild Horses fuel tank is designed to maximize space, and you must be careful not to bend or damage the fuel connections when jacking the tank into place.
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Remove the old tank
Removing the old tank is a crucial step in installing a new fuel tank, such as the Wild Horses 23-gallon fuel tank. Here is a detailed guide on how to remove the old tank:
First, ensure that the fuel tank you are removing is almost empty, with only a gallon or two of fuel remaining. This makes the tank easier to handle during the removal process. It is important to work with caution when dealing with fuel and have a safe place to store the fuel you remove.
Next, prepare your workspace by power washing or hosing down the area under the bed where the old tank is located. This step is important as it helps to minimise the amount of dust and debris that can fall into your eyes or onto the fuel tank during the removal process.
After the area is cleaned, you can begin to remove the old tank by first detaching the strap that secures it in place. Be careful when handling the old tank, as it may be heavy and cumbersome to manoeuvre. It is recommended to have an extra pair of hands to assist with this step if possible.
Once the tank is removed, you will need to deal with the old spacers that were used to prevent the old tank from touching the bed. Remove these spacers carefully, ensuring that you do not damage the surrounding components.
Finally, take the time to inspect the area where the old tank was located. Look out for any signs of damage, corrosion, or debris that may have accumulated over time. Ensure that the area is clean and ready for the installation of the new Wild Horses 23-gallon fuel tank.
By following these steps, you can safely and effectively remove the old fuel tank, setting the stage for a smooth installation process for your new Wild Horses 23-gallon fuel tank.
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Prepare the new tank
To prepare a new Wild Horses 23-gallon fuel tank for installation, there are several steps you should follow. Firstly, run the existing tank down to a minimum amount of fuel. This makes it easier to manage the removal of the old tank and ensures you can handle it gracefully. You should aim to have around a gallon or two of fuel left in the tank. This step should take about an hour.
Next, you need to prepare the working area. Powerwash or hose down the area where the old tank was located to minimise dust and clay that may cause irritation during the installation process.
After this, you can begin to remove the old tank and its components. Remove the old spacers that were in place to prevent the old tank from touching the bed. If your old tank has a fuel hose, you may need to replace it. Ensure you use a fuel line that is rated for this use.
If you are installing the new tank with a body lift, you should take this into account when mounting the tank. The tank may shift slightly once the body is in place, so be prepared to adjust it accordingly.
Finally, it is important to note that the supplied hardware may not be of the best quality. For example, the supplied bolts may not be the desired grade, so you may want to discard them and use your own bolts of a higher grade.
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Install the new tank
Before installing the new tank, ensure that you have run the old tank down to a minimum of fuel. With a gallon or two in it, it is still easily manageable to get the old tank down gracefully. It should take about an hour to remove the strap, old tank, and put the old gas somewhere safe. Powerwash or hose down the working area under the bed where the old tank was to prevent dust and clay from falling in your eyes during installation.
Next, remove the old spacers that prevent the old tank from touching the bed. Be careful when jacking the new tank into place. The tank was designed to maximize all the space underneath and between the frame, so you could bend or damage the fuel connections on the frame when jacking. You may want to invite a friend over to help with this step.
If you purchased the tank specifically for EFI, the filter is already assembled and in the tank. The pickup "sock" is the filter and should already be in place. If you are using an external filter, a finer one on the frame that gets changed every 50,000 miles or so would be a good idea to keep things out of the injectors.
If you are installing the electric pump inside the tank, a 1 1/4 inch electric conduit bracket works perfectly to bolt this inside the tank in the holes that are pre-drilled. Test run the fuel pump bracket all assembled before putting it in the tank.
Finally, if you are using bolts to secure the tank, ensure that they are the correct grade and length.
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Test the new tank
Before testing the new tank, ensure that you have followed the installation instructions carefully. The installation process may take up to 10 hours, or 15-20 hours if you want to clean and paint the tank before bolting it into place.
To test the new tank, you should first run the tank down to a minimum level of fuel. This makes the process safer and easier to manage. With only a gallon or two of fuel in the tank, you can then proceed to carefully remove the old tank and place it somewhere safe.
Next, power wash or hose down the area where the old tank was installed. This will help to remove any dust and debris that may have accumulated during the installation process.
Now, you can begin the testing process. Invite a friend to help you manoeuvre the new tank into place, being careful not to bend or damage the fuel connections. Once the new tank is in position, you can start the engine and check for any signs of fuel leakage.
If the new tank is functioning properly, the fuel gauge should indicate the correct fuel level, and there should be no signs of fuel leakage. If there are any issues, such as a ruptured fuel hose or fuel starvation, further troubleshooting and adjustments may be required.
It is important to note that the testing process may vary depending on the specific vehicle and fuel tank setup. Always refer to the manufacturer's instructions and take the necessary safety precautions when working with fuel systems.
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Frequently asked questions
It takes around three hours to install the tank, but if you want to do it properly, it could take up to 10 hours. If you want to clean it up and do some painting and undercoating before bolting up the new tank, it could take closer to 15-20 hours.
The Wild Horses 23-gallon fuel tank has a capacity of 23 gallons or 87 liters. It offers more fuel capacity than the original tanks, adding 10 gallons of extra fuel capacity over the stock tank.
The Wild Horses 23-gallon fuel tank is 14 GA thick and is made of stainless steel. It has a 3/16 inch thick form-fitting skid plate and is adjustable to fit 0-3 inch body lifts.
The Wild Horses 23-gallon fuel tank is compatible with 66-77 Ford Broncos. It is designed for carbureted or EFI engines and can be used with or without a body lift.
Here are some tips for installing the Wild Horses 23-gallon fuel tank:
- Run the old tank down to a minimum fuel level before removing it.
- Power wash or hose down the working area to minimize dust and debris.
- Be careful when jacking the new tank into place to avoid damaging the fuel connections.
- Consider inviting a friend over to help maneuver the tank into place.
