Why such small gas tanks in newer cars

2021 F150 5.0 36 gallon tank 19 mpg 684 miles (minus a little reserve). I don't see a problem...

Until you are under 100 miles left in the tank and have to fill it! That and parking are the only drawbacks I have with my 15 F150.
 
I’d say it’s a variety of factors, all already covered here.

First off, packaging. Designing a car is complicated and the bigger the tank the more effort you have to put into finding a place to put it while avoiding drivetrain components without encroaching on the interior or cargo space of the vehicle.

Next, safety… it’s easier to protect a smaller fuel tank from a crash.

Next, cost… parts cost money. Smaller tank is cheaper.

Finally, fuel economy. I don’t know how the fuel economy tests are done but if we assume they are done at a fixed percentage of fuel in the tank the smaller tank will mean a lighter vehicle which will mean better MPG results.
I'm guessing that the proliferation of 4WD/AWD vehicles is making it even more difficult to make space for a gas tank as well.
 
Why have they downsized gas tanks? A family member recently bought a 24 CRV. It has a 14 gallon gas tank. She is having to frequent the pump more often than her older car. My Tucson has about a 15 gallon tank. Why can't they have at least a 18 gallon tank where you could go for a while without filling up. What gives? Is this some kind of EPA mandate?

Simple. Weight reduction to help meet the EPA MPG requirement for a manufacturers fleet. The small cars take the hit so they can make pickups and SUVs.

Just my $0.02
 
I remember back in the day, my dad's 70 full size Chevy stationwagon got 6 or 7 miles per gallon (Pittsburgh hills and stop and go traffic ), with a 22 gallon tank. Thats 132 to 154 miles full to empty and of course we never ran it empty. And some are not happy with 300 + miles per tank and much nicer displays of remaining range.
 
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I'm guessing that the proliferation of 4WD/AWD vehicles is making it even more difficult to make space for a gas tank as well.

And hybrids. The trunk of a PHEV fusion is barely deep enough to fit my work backpack; a whole 8.2ft^3. It's a shame because it's a really smooth riding car with ~550miles on a 12.5gal tank.

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More cargo space. More fuel. More people prefer the former. And is it really that big a deal going to the station 2-3 extra times a year?
A year? Maybe more like 2-3 times a week.

I get fantastic mileage in my Honda Fit but its annoying having to stop and fill it so often (the tank is tiny and located under the front seats). Even a couple more gallons would have made a big difference. At least it isn't expensive.
 
It's all about weight reduction.
No way. If that was they case they’d stop increasing vehicle size, tire & wheel sizes, options, and everything else.

It’s to make driving more inconvenient and less noticeable of a gap between EVs & gas cars.

I’ve gone as far as 850 miles on one tank in my truck under ideal conditions. Still had right at 1 gallon left in the tank.
 
Until you are under 100 miles left in the tank and have to fill it! That and parking are the only drawbacks I have with my 15 F150.
I sure miss my last F150xlt. Mine came with the towing package (needed for my boats & camper) and two gas tanks beneath & behind the single cab with the long bed. Two tanks made for some mighty easy long hauls......
 
Why have they downsized gas tanks? A family member recently bought a 24 CRV. It has a 14 gallon gas tank. She is having to frequent the pump more often than her older car. My Tucson has about a 15 gallon tank. Why can't they have at least a 18 gallon tank where you could go for a while without filling up. What gives? Is this some kind of EPA mandate?
This has been a steady issue starting in the early 90’s

The old 82 diesel suburban had a 42 gallon tank which gave at least 800 miles of range

My 2001 dodge you are lucky to get 24 gallons to fit and due to it’s mediocre mpgs that means a short range.

Several of my cars have whopping 8 gallon tanks which is a real problem on multi thousand mile road trips out west.

The New Dodge Hornet has a 13.5 gallon tank but in city driving and winter highway driving it’s very common on both versions to only net about a 250 mile range to the light, who wants to be bothered with that?
 
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