Fuel Tanks Pickup Trucks: Your Comprehensive Guide to Capacity, Performance, and Practicality

Fuel Tanks Pickup Trucks: Your Comprehensive Guide to Capacity, Performance, and Practicality pickup.truckstrend.com

Pickup trucks are the workhorses of the automotive world, renowned for their versatility, towing capabilities, and rugged durability. At the heart of their utility lies the fuel tank – a component often overlooked but critical to a truck’s range, performance, and overall practicality. From daily commutes to cross-country hauls, job site operations to remote outdoor adventures, the capacity and reliability of your pickup truck’s fuel tank directly impact your ability to get the job done or reach your destination without interruption.

This comprehensive guide delves into the world of pickup truck fuel tanks, exploring everything from standard OEM setups to advanced aftermarket solutions. We’ll uncover the different types, the benefits of expanded capacity, crucial considerations for selection, installation tips, maintenance essentials, and common issues, ensuring you’re well-equipped to make informed decisions about this vital component.

Fuel Tanks Pickup Trucks: Your Comprehensive Guide to Capacity, Performance, and Practicality

The Heart of the Haul: Understanding Stock Fuel Tanks

Every pickup truck comes equipped with an Original Equipment Manufacturer (OEM) fuel tank designed to meet the average driver’s needs. These tanks are meticulously engineered to fit within the truck’s chassis, typically mounted under the bed or between the frame rails, optimizing weight distribution and ground clearance.

Materials and Construction:

• Steel: Historically common, steel tanks are robust and durable. However, they are susceptible to rust and corrosion over time, especially in areas where road salt is used or humidity is high. Modern steel tanks often feature advanced coatings to mitigate this.
• Polyethylene (Plastic): Increasingly prevalent, plastic fuel tanks are lighter, corrosion-proof, and more resistant to impact damage than steel. Their flexibility allows for more complex shapes, enabling manufacturers to maximize capacity within available space.
• Placement: Most OEM tanks are strategically placed to balance the truck, usually centered or slightly rearward of the cab, to minimize impact on handling as fuel levels change.

Capacity and Limitations:
OEM fuel tank capacities vary significantly by truck model, trim level, and manufacturer, typically ranging from 20 to 36 gallons. While sufficient for most daily driving, these capacities can become a limiting factor for:

• Long-distance towing: Heavy loads significantly reduce fuel economy.
• Remote area travel: Where fuel stations are scarce.



• Commercial use: Frequent refueling can lead to downtime and reduced productivity.
• Off-roading: Extended trips away from civilization.

Understanding these limitations is often the first step toward considering aftermarket fuel solutions.

Expanding Horizons: Aftermarket and Auxiliary Fuel Tanks

For pickup owners seeking greater range, convenience, or the ability to fuel other equipment, the aftermarket offers a robust array of solutions. These can be broadly categorized into replacement tanks and auxiliary/transfer tanks.

1. Replacement Fuel Tanks

These tanks are designed to directly replace your OEM tank with a larger capacity unit, fitting into the same factory location.

• Benefits: Increased range without sacrificing bed space, maintains factory appearance.
• Considerations: Installation can be complex, often requiring professional help. May slightly reduce ground clearance depending on design.
• Materials: Typically constructed from heavy-gauge steel or aluminum for durability and corrosion resistance.

2. Auxiliary/Transfer Fuel Tanks

These are supplementary tanks installed in addition to the OEM tank, providing extra fuel storage. They come in various configurations:

• In-Bed Tanks: The most common type, these tanks sit in the truck bed. They are available in various shapes, including rectangular, L-shaped (often combined with a toolbox), and wedge designs.
  • Pros: Easy installation, highly visible fuel level, versatile for fueling other equipment.
  • Cons: Occupies valuable bed space, affects cargo capacity.
• Under-Bed Auxiliary Tanks: Less common but gaining popularity, these tanks are designed to fit discreetly under the truck bed, often replacing a spare tire location or occupying unused frame space.
  • Pros: No loss of bed space, maintains clean aesthetic.
  • Cons: More complex installation, limited capacity due to space constraints, often requires relocation of spare tire.
• Side-Mount Tanks: Designed to mount alongside the truck bed or under the cab, though less common for pickups specifically.

Materials for Aftermarket Tanks:

• Aluminum: Lightweight, excellent corrosion resistance, attractive finish. Generally more expensive.
• Steel: Heavy-duty, durable, and more affordable. Can be prone to rust if not properly coated.
• Polyethylene: Lightweight, affordable, and resistant to corrosion. Primarily used for non-DOT compliant tanks or for specific applications like DEF (Diesel Exhaust Fluid) tanks.

Benefits Beyond the Basics: Why Upgrade Your Fuel Capacity?

Investing in an aftermarket fuel tank offers a multitude of advantages that go beyond simply extending your driving range:

• Extended Range & Reduced "Range Anxiety": The primary benefit. Drive further without worrying about finding the next gas station, especially in remote areas or when towing heavy loads that significantly reduce fuel economy.
• Cost Savings & Fuel Arbitrage: Buy fuel when prices are low and avoid paying premium prices in less competitive or remote locations. This can lead to substantial savings over time, especially for high-mileage drivers or commercial users.
• Increased Productivity & Efficiency: For businesses, fewer stops for fuel mean more time on the job site, delivering goods, or completing tasks. This translates directly to improved operational efficiency and profitability.
• Fueling Other Equipment: Transfer tanks are invaluable for agricultural, construction, or recreational users who need to refuel ATVs, UTVs, tractors, generators, or other machinery on-site without hauling separate fuel cans.
• Emergency Preparedness: A larger fuel reserve can be crucial in emergency situations, power outages, or natural disasters, ensuring you have fuel for your truck or to power essential equipment.
• Convenience: Simply put, less frequent stops at gas stations save time and hassle, making long trips more enjoyable.

Navigating the Choices: Key Considerations for Your Fuel Tank

Choosing the right aftermarket fuel tank requires careful thought. Here are the critical factors to consider:

• Capacity Needs: How much extra fuel do you realistically need? Balance desired range with the physical space available and the added weight.
• Material: Aluminum for weight savings and corrosion resistance; Steel for durability and budget; Polyethylene for specific non-fuel applications or smaller tanks.
• Placement & Space Impact: Will an in-bed tank interfere with your cargo needs, fifth-wheel hitch, or tonneau cover? Can you sacrifice your spare tire location for an under-bed tank?
• Fuel Type Compatibility: Ensure the tank is rated for gasoline, diesel, or DEF. Never mix fuel types or use a tank not designed for the specific fuel.
• Legal & Safety Regulations (DOT Compliance): This is paramount for transfer tanks. Tanks used for transporting fuel on public roads (especially diesel for commercial purposes) must be DOT (Department of Transportation) compliant, adhering to strict standards for construction, baffling, venting, and labeling. Check local and state regulations as well.
• Installation Complexity: Some tanks are relatively simple DIY projects, while others (especially replacement or under-bed auxiliary tanks) may require professional installation due to complex plumbing, electrical work, or frame modifications.
• Budget: Prices vary widely based on material, capacity, brand, and features. Don’t forget to factor in installation costs if you’re not doing it yourself.
• Integration with Truck Systems: How will the new tank integrate with your truck’s fuel system? Will it feed directly into the main tank, or will it require a separate pump for transfer? Consider fuel gauges and switching mechanisms.

Installation & Upkeep: Ensuring Longevity and Safety

Proper installation and routine maintenance are crucial for the safe and reliable operation of any fuel tank.

Installation:

• Professional vs. DIY: While some in-bed transfer tanks can be installed by a competent DIYer, replacement tanks or complex auxiliary systems that tie into the truck’s main fuel system are best left to experienced mechanics. Improper installation can lead to leaks, fuel delivery issues, or dangerous situations.
• Safety First: Always disconnect the battery, work in a well-ventilated area, have a fire extinguisher handy, and avoid any ignition sources. Ensure the truck is securely supported if working underneath.
• Key Steps (General):
  1. Mounting: Securely fasten the tank to the truck frame or bed using appropriate hardware.
  2. Plumbing: Connect fuel lines, ensuring they are properly routed, secured, and free from kinks or chafing. Use fuel-grade hoses and fittings.
  3. Electrical: Wire any pumps, gauges, or switching systems according to manufacturer instructions.
  4. Venting: Ensure proper venting to prevent vacuum or pressure buildup, which can hinder fuel flow or damage the tank.
  5. Leak Check: After installation, fill the tank with a small amount of fuel and thoroughly inspect all connections for leaks before a full fill-up.

Maintenance:

• Regular Inspections: Periodically check the tank, lines, and connections for any signs of leaks, corrosion, cracks, or damage.
• Fuel Filters: If your auxiliary tank has its own pump and filter, replace the filter regularly to prevent contaminants from reaching your truck’s engine.
• Venting System: Ensure the vent lines are clear and unobstructed.
• Cleanliness: Keep the area around the tank free of debris.
• Winterization/Storage: If storing the truck or tank for an extended period, consider filling the tank to prevent condensation and adding a fuel stabilizer.

Troubleshooting Common Fuel Tank Issues

Even with proper care, issues can arise. Here’s how to approach common problems:

• Leaks: The most critical issue. Identify the source (loose fitting, cracked tank, compromised line). For minor leaks, specialized sealants might work, but often replacement of the damaged component or the tank itself is necessary. Do not drive with a leaking fuel tank.
• Fuel Gauge Inaccuracies: Can be caused by a faulty sending unit in the tank, wiring issues, or calibration problems (especially with aftermarket systems). Consult the tank manufacturer’s instructions for troubleshooting or recalibration.
• Slow Fueling/Pressure Issues: Often a sign of a clogged or improperly routed vent line. Ensure the vent is clear and not kinked. A faulty fuel cap can also cause vacuum issues.
• Contamination: Water, rust, or debris in the fuel can cause engine problems. Regular use of fuel additives and proper filtration can help. If contamination is severe, the tank may need to be drained and cleaned.
• Pump Failure (Transfer Tanks): Check electrical connections, fuses, and the pump motor itself. Many transfer pumps are user-serviceable for basic issues.

Practical Advice for the Discerning Pickup Owner

• Assess Your Needs Honestly: Don’t just buy the biggest tank. Consider your actual driving habits, work requirements, and cargo needs.
• Prioritize Safety & Compliance: Always choose DOT-compliant tanks for fuel transfer on public roads. Never compromise on safety features like baffling and proper venting.
• Research Thoroughly: Read reviews, compare brands, and understand the installation requirements before purchasing.
• Consider Professional Installation: For complex systems or if you’re uncomfortable with fuel system work, professional installation is a wise investment.
• Factor in Payload: Remember that every gallon of diesel weighs approximately 7 pounds, and gasoline around 6 pounds. A large auxiliary tank full of fuel can significantly impact your truck’s payload capacity.

Fuel Tanks Pickup Trucks: Estimated Price Guide

Please note: Prices are highly variable and depend on brand, material, capacity, features, and the complexity of the design. Installation costs are separate and can range from a few hundred to over a thousand dollars for complex systems.

Fuel Tank Type	Material	Capacity Range (Gallons)	Typical Price Range (USD)	Key Features/Notes
OEM Replacement (Standard)	Steel / Plastic	20 – 36	$200 – $800	Direct fit for stock location, basic replacement.
OEM Replacement (Larger Cap.)	Steel / Aluminum	40 – 70+	$800 – $2,500+	Fits stock location but offers increased capacity, often more complex installation.
In-Bed Auxiliary (Rectangular)	Aluminum	50 – 100+	$700 – $2,000+	Lightweight, corrosion-resistant, takes up bed space. May include pump.
In-Bed Auxiliary (Rectangular)	Steel	50 – 100+	$500 – $1,500+	Durable, heavier, more affordable. May include pump.
In-Bed L-Shaped (Tank/Toolbox Combo)	Aluminum	40 – 90	$1,000 – $2,500+	Combines fuel storage with secure tool storage. Popular for commercial use.
In-Bed L-Shaped (Tank/Toolbox Combo)	Steel	40 – 90	$700 – $1,800+	Heavier duty, more budget-friendly combo.
Under-Bed Auxiliary	Aluminum / Steel	30 – 60	$1,200 – $3,000+	Frees up bed space, complex installation, often requires spare tire relocation.
Diesel Exhaust Fluid (DEF) Tanks	Polyethylene	5 – 15	$150 – $500	Separate tanks for DEF systems in modern diesel trucks. Not for fuel.

Frequently Asked Questions (FAQ)

Q1: Are aftermarket fuel tanks safe?
A1: Yes, reputable aftermarket fuel tanks are designed and manufactured to high safety standards. However, safety depends heavily on proper installation and adherence to regulations, especially for transfer tanks. Always ensure tanks are DOT compliant if used for transporting fuel on public roads.

Q2: Do I need a special license to operate a truck with an auxiliary fuel tank?
A2: For personal use, generally no. However, if you are transporting large quantities of fuel for commercial purposes (e.g., over 119 gallons per container or 1,000 gallons total for certain hazardous materials), you may fall under HazMat regulations and require a Commercial Driver’s License (CDL) with a hazardous materials endorsement. Always check local, state, and federal regulations (e.g., DOT, FMCSA) applicable to your specific use.

Q3: Will installing an aftermarket fuel tank void my truck’s warranty?
A3: Generally, no. The Magnuson-Moss Warranty Act protects consumers from manufacturers voiding warranties due to aftermarket parts, unless they can prove the aftermarket part directly caused the failure. However, if an improperly installed fuel tank leads to damage to the fuel system or other components, the repair of those damaged components might not be covered. It’s always wise to use reputable products and consider professional installation.

Q4: How much extra fuel capacity do I really need?
A4: This depends on your typical usage. For long-distance towing or remote travel, calculate your truck’s average MPG under load and determine how many miles you want to travel between fill-ups. For example, if your truck gets 10 MPG towing and you want a 600-mile range, you’d need 60 gallons total. If your stock tank is 30 gallons, an additional 30-gallon auxiliary tank would be sufficient.

Q5: Can I install an aftermarket fuel tank myself?
A5: Simple in-bed transfer tanks with self-contained pumps are often DIY-friendly for those with basic mechanical skills. However, replacement tanks or auxiliary tanks that integrate with the truck’s main fuel system are significantly more complex, involving fuel lines, electrical wiring, and potentially fuel pump/sending unit calibration. For these, professional installation is highly recommended to ensure safety and proper operation.

Q6: What’s the difference between an auxiliary and a transfer tank?
A6: These terms are often used interchangeably, but there’s a subtle distinction. An auxiliary tank typically refers to a tank plumbed directly into the truck’s main fuel system to extend its driving range. A transfer tank usually implies a tank primarily used to transport fuel to fill other equipment (e.g., ATVs, generators) and may or may not be connected to the truck’s main fuel system. Many tanks are designed to function as both.

Conclusion

The fuel tank in your pickup truck is far more than just a reservoir; it’s a critical component dictating your truck’s range, utility, and efficiency. Whether you rely on your stock tank or choose to enhance your capabilities with an aftermarket solution, understanding the various types, benefits, and considerations is key. By making informed choices regarding capacity, material, and safety, you can optimize your pickup truck for whatever the road—or the job site—throws your way, ensuring that you’re always ready for the next adventure or the next task. Drive further, work smarter, and embrace the true potential of your pickup truck.