Fuel Tanks For Pickup Trucks: Expanding Your Range and Capability

Fuel Tanks For Pickup Trucks: Expanding Your Range and Capability pickup.truckstrend.com

Pickup trucks are the workhorses of the automotive world, renowned for their versatility, towing capacity, and rugged dependability. Whether you’re hauling equipment to a job site, embarking on a cross-country road trip, or venturing deep into the backcountry for an overlanding adventure, the one limitation that often arises is fuel range. This is where the topic of fuel tanks for pickup trucks becomes critical, extending beyond just the standard factory-installed unit. Understanding the different types, benefits, and considerations of pickup truck fuel tanks can significantly enhance your vehicle’s utility and your peace of mind.

This comprehensive guide will delve into everything you need to know about fuel tanks for pickup trucks, from their fundamental role to advanced aftermarket solutions, ensuring you’re well-equipped for any journey or task.

Fuel Tanks For Pickup Trucks: Expanding Your Range and Capability

The Foundation: Your Pickup’s Stock Fuel Tank

Every pickup truck comes equipped with a factory-installed fuel tank, designed to meet the general needs of the average driver. These tanks typically range in capacity from 20 to 36 gallons, depending on the truck’s make, model, and configuration (e.g., short bed vs. long bed, gasoline vs. diesel).

Key Characteristics of Stock Tanks:

• Material: Often constructed from stamped steel or high-density polyethylene (HDPE) plastic. Steel tanks are robust but susceptible to rust if not properly coated, while plastic tanks are lighter, corrosion-resistant, and more flexible for complex shapes.
• Placement: Usually mounted underneath the truck bed or within the frame rails, optimized for weight distribution and ground clearance.
• Integration: Fully integrated with the truck’s fuel delivery system, including fuel pump, sending unit, and emissions controls.

While adequate for daily commutes and short trips, the limitations of a stock fuel tank become apparent for specific use cases. Long-distance towing, remote work sites, off-road expeditions far from civilization, or simply the desire to reduce frequent stops at the gas station often lead truck owners to seek expanded fuel solutions.

Why Upgrade or Add an Auxiliary Fuel Tank?

The decision to modify or add to your pickup’s fuel capacity stems from a variety of practical needs and desires:

1. Extended Range: This is the most common reason. For long hauls, cross-country travel, or towing heavy loads that significantly reduce fuel economy, an extended range tank drastically cuts down on fuel stops, saving time and hassle.



2. Off-Grid Adventures & Overlanding: When exploring remote areas where gas stations are scarce or nonexistent, auxiliary fuel becomes a necessity for peace of mind and safe return.
3. Commercial & Fleet Use: Businesses relying on pickups for deliveries, service calls, or construction benefit from fewer fueling stops, maximizing uptime and productivity. Bulk fuel purchasing at lower prices can also lead to significant savings.
4. Fuel Price Arbitrage: In areas with fluctuating fuel prices, a larger tank allows you to fill up when prices are low and avoid expensive areas, leading to long-term savings.
5. Emergency Preparedness: Having extra fuel on board can be crucial in emergency situations, power outages, or natural disasters.
6. Powering Auxiliary Equipment: Many auxiliary tanks are designed to transfer fuel not just to the truck’s main tank, but also to external equipment like generators, ATVs, or construction machinery.

Types of Aftermarket Fuel Tanks for Pickups

Aftermarket fuel solutions for pickup trucks generally fall into two main categories: auxiliary/transfer tanks and replacement tanks.

1. Auxiliary/Transfer Tanks (In-Bed)

These are the most popular aftermarket option, designed to sit in the truck’s bed and hold additional fuel. They can be plumbed into the truck’s main fuel system or used for simple fuel transfer to other vehicles or equipment.

• Description: Self-contained units that carry extra fuel. They are either plumbed to transfer fuel to the main tank (transfer tank) or simply store it for external use (auxiliary tank, though often used interchangeably with transfer tank).
• Materials:
  • Aluminum: Lightweight, corrosion-resistant, excellent for fuel. Often preferred for diesel.
  • Steel: Very durable, heavier, but prone to rust if not properly coated. Good for all fuel types.
  • Polyethylene (Plastic): Lighter and more affordable, but generally limited to certain fuel types (check manufacturer specifications, often not recommended for gasoline due to permeability and safety concerns).
• Shapes & Mounting:
  • Rectangular: Simple box shape, maximizes capacity for its footprint.
  • L-Shaped: Designed to fit around a wheel well or tool box, optimizing bed space. Often integrated with a toolbox on top.
  • Wheel Well Tanks: Slim tanks designed to fit over or behind the wheel wells, leaving the main bed floor open.
  • Tool Box Combo Tanks: Integrate a fuel tank directly into the base of a truck bed toolbox, offering both storage and fuel capacity.
• Transfer Methods (for Transfer Tanks):
  • Electric Pump: Most common and convenient. A 12V electric pump (often rotary vane or gear pump) transfers fuel from the auxiliary tank to the main tank with the flick of a switch. Flow rates vary.
  • Gravity Feed: Less common for vehicle transfer, more for equipment. Relies on gravity, meaning the auxiliary tank must be higher than the main tank’s fill neck. Often requires careful plumbing and valving.
• Considerations:
  • DOT Regulations: Crucial for safety and legality. Tanks must meet specific Department of Transportation (DOT) standards for material, construction, baffling, and venting, especially if transporting diesel or gasoline.
  • Venting: Proper venting is essential to prevent pressure buildup or vacuum, ensuring safe operation.
  • Baffling: Internal baffles prevent fuel sloshing, which can affect vehicle handling and tank integrity.
  • Payload: Remember the weight of the fuel (approx. 6.7 lbs/gallon for diesel, 6 lbs/gallon for gasoline) adds to your truck’s payload, which can impact suspension and braking.

2. Replacement/Larger Capacity Tanks

Instead of adding a tank to the bed, these tanks directly replace the factory fuel tank with a larger-capacity unit that fits in the original location.

• Description: Designed as a direct bolt-in replacement for the OEM tank, often increasing capacity by 10-30+ gallons.
• Benefits:
  • No Bed Space Loss: The primary advantage, preserving valuable bed space for cargo.
  • Seamless Integration: Maintains the truck’s original aesthetics and weight distribution.
  • Ease of Use: Operates just like the stock tank, no manual transfer needed.
• Challenges:
  • Installation Complexity: Typically requires professional installation due to the need to drop the existing tank, disconnect fuel lines, and ensure proper fitment.
  • Cost: Generally more expensive than auxiliary tanks due to specialized design and installation.
  • Ground Clearance: While designed to fit the original location, ensure the larger capacity doesn’t compromise critical ground clearance.
• Materials: Similar to OEM, often steel or durable plastic, engineered for direct fit and robust performance.

Key Considerations When Choosing a Fuel Tank

Selecting the right fuel tank involves more than just picking a size. Here are critical factors to weigh:

1. Capacity Requirements: How much extra fuel do you realistically need? Calculate your typical range and how much you want to extend it. Consider your truck’s average MPG and the longest distance you anticipate traveling without refueling.
2. Fuel Type: Ensure the tank is rated for the fuel you intend to carry (gasoline, diesel, or both). Diesel tanks are generally simpler, while gasoline tanks have stricter venting and material requirements due to flammability.
3. Material Durability:
   • Aluminum: Lightweight, corrosion-resistant, ideal for diesel. More expensive.
   • Steel: Heavy-duty, durable, but requires proper coating to prevent rust. More affordable than aluminum.
   • Polyethylene: Lightest, most affordable, but may not be suitable for all fuel types or extreme conditions.
4. Compliance & Regulations (Crucial!):
   • DOT Compliance: Tanks must be DOT-compliant (e.g., DOT 406 for flammable liquids, or specifically designed for non-flammable combustibles like diesel). This covers construction, materials, pressure relief, and labeling.
   • State & Local Laws: Some states have specific regulations regarding fuel transport capacity or transfer methods. Always verify local laws.
   • EPA & CARB: Emissions regulations can impact certain setups, especially if integrating with the main fuel system.
5. Installation Method:
   • DIY vs. Professional: Auxiliary tanks are often DIY-friendly with basic tools. Replacement tanks typically require professional expertise due to their complexity and safety implications.
   • Mounting: Ensure the tank comes with robust mounting hardware and clear instructions for secure attachment to your truck’s frame or bed.
6. Safety Features:
   • Baffling: Internal dividers prevent fuel slosh, improving vehicle handling and preventing tank damage.
   • Pressure Relief Valves: Essential for safe operation, preventing pressure buildup from temperature changes.
   • Secure Caps & Vents: Prevent spills and ensure proper ventilation.
   • Roll-Over Protection: Designed to prevent leaks in case of an accident.
7. Compatibility: Verify the tank is designed to fit your specific truck make, model, and year. Check dimensions, especially for in-bed tanks, to ensure it clears wheel wells, tonneau covers, or other accessories.
8. Pump Type (for Transfer Tanks):
   • Manual Hand Pump: Simple, reliable, but slow and requires effort.
   • 12V Electric Pump: Convenient, faster, but requires wiring and a power source. Consider flow rate (GPM – gallons per minute).
9. Warranty & Manufacturer Reputation: Invest in a tank from a reputable manufacturer with a solid warranty to ensure quality and support.

Installation Tips and Maintenance

Safety First:

• Always work in a well-ventilated area.
• Disconnect the truck’s battery.
• Have a fire extinguisher nearby.
• Avoid open flames, sparks, or smoking.
• Wear appropriate PPE (gloves, eye protection).

Installation (General Tips):

• Mount Securely: The tank must be bolted directly to the truck’s bed or frame. Do not rely on tie-down straps alone.
• Proper Plumbing: Use fuel-rated hoses, clamps, and fittings. Ensure all connections are tight and leak-free. Install an inline fuel filter for transfer systems.
• Ventilation: Ensure the tank is properly vented to the atmosphere (often via a rollover vent valve) to prevent pressure/vacuum issues.
• Electrical (for electric pumps): Wire the pump directly to the truck’s battery with an inline fuse. Use marine-grade wiring for durability.
• Testing: After installation, fill the tank with a small amount of fuel and check thoroughly for any leaks before a full fill-up.

Maintenance:

• Regular Inspection: Periodically check the tank, lines, and fittings for leaks, cracks, or damage.
• Cleanliness: Keep the tank exterior clean.
• Filter Replacement: If using a transfer pump, replace its fuel filter as recommended by the manufacturer.
• Fuel Quality: Use clean, high-quality fuel to prevent issues with your truck’s fuel system.

Potential Challenges and Solutions

• Weight & Payload: A full auxiliary tank adds significant weight.
  • Solution: Consider upgrading your truck’s suspension (e.g., airbags, helper springs, heavier-duty leaf springs) to maintain ride height and handling, especially if frequently hauling heavy loads. Stay within your truck’s Gross Vehicle Weight Rating (GVWR).
• Bed Space Consumption: In-bed auxiliary tanks take up valuable cargo space.
  • Solution: Opt for L-shaped tanks that fit with toolboxes, wheel well tanks, or consider a replacement tank if bed space is paramount.
• Cost: Aftermarket fuel tanks can be a significant investment.
  • Solution: View it as a long-term investment in convenience, extended capability, and potential fuel savings. Compare options and features versus price.
• Regulations & Legality: Navigating complex DOT and local regulations can be confusing.
  • Solution: Purchase tanks explicitly advertised as DOT-compliant. Research your specific state and local laws, especially if carrying gasoline. When in doubt, consult with a professional installer or regulatory body.
• Fuel Sloshing/Surge: Unbaffled tanks can cause fuel to slosh around, affecting vehicle stability.
  • Solution: Choose tanks with internal baffles to minimize fuel movement.

Hypothetical Pricing Table for Fuel Tanks For Pickup Trucks

Please note: These prices are estimates and can vary significantly based on brand, material quality, features, current market conditions, and installation costs.

Tank Type	Material	Capacity (Gallons)	Estimated Price Range (USD)	Key Features / Notes
In-Bed Auxiliary/Transfer Tanks
Standard Rectangular	Aluminum	30-50	$600 – $1,200	Lightweight, corrosion-resistant, often includes mounting tabs. Diesel preferred.
Standard Rectangular	Steel	30-50	$400 – $900	Durable, heavier, good value. Rust-resistant coating important.
L-Shaped Combo	Aluminum	50-90	$1,000 – $2,500	Integrates with toolbox, maximizes bed utility. Diesel preferred.
L-Shaped Combo	Steel	50-90	$800 – $2,000	Cost-effective combo solution.
Wheel Well Tank	Aluminum	25-40 (each side)	$700 – $1,500	Slim design, keeps bed floor open. Can be bought individually or as a pair.
Polyethylene Transfer	Polyethylene	25-60	$300 – $800	Lighter, more affordable. Check fuel compatibility (often diesel only).
Transfer Pumps (Add-on)
Manual Hand Pump	Cast Iron	N/A	$50 – $150	Basic, reliable, slow.
12V Electric Pump	Aluminum/Steel	N/A	$150 – $500	Various flow rates (8-20 GPM). Includes nozzle, hose, wiring.
Replacement Tanks (Larger Capacity)
OEM Replacement	Steel/HDPE	40-60	$1,000 – $2,500	Direct fit, no bed space lost. Requires professional installation. Diesel or Gasoline specific.
Custom Fabrication	Aluminum	60+	$2,000 – $5,000+	For highly specific needs, off-road builds. High cost, specialized installation.

Note: Installation costs for complex replacement tanks or custom setups can add $300 – $1000+ to the total price.

Frequently Asked Questions (FAQ)

Q1: Is it legal to carry extra fuel in my truck bed?
A1: Yes, but with strict regulations. Auxiliary/transfer tanks must be DOT-compliant and rated for the fuel type. There are limits on capacity for non-commercial use in some states. Always check your local and state regulations.

Q2: Can I put gasoline in a diesel transfer tank?
A2: No, never. Diesel and gasoline have different properties and safety requirements. Tanks designed for diesel may not be suitable for gasoline due to venting, material compatibility, and flammability concerns. Always use a tank specifically rated for the fuel type you intend to carry.

Q3: Will adding an auxiliary tank affect my truck’s warranty?
A3: Generally, adding an aftermarket accessory like an auxiliary tank will not void your entire vehicle warranty. However, if the auxiliary tank or its installation directly causes a failure in a related vehicle system (e.g., fuel pump, suspension), that specific repair might not be covered. It’s best to use reputable products and professional installers.

Q4: How much weight does a full auxiliary tank add to my truck?
A4: Diesel weighs approximately 6.7 lbs per gallon, and gasoline is about 6 lbs per gallon. A 50-gallon diesel tank would add roughly 335 lbs of fuel weight, plus the weight of the tank itself (e.g., 50-100 lbs for aluminum). Always factor this into your truck’s payload capacity.

Q5: What’s the difference between a "transfer tank" and an "auxiliary tank"?
A5: The terms are often used interchangeably. Technically, a "transfer tank" is designed to move fuel from the tank to your truck’s main fuel system or other equipment, often with an integrated pump. An "auxiliary tank" simply holds extra fuel, which you might manually siphon or pump out. Most tanks sold for pickup beds are designed for transfer.

Q6: Do I need baffles in my fuel tank?
A6: Yes, baffles are highly recommended and often legally required for larger tanks. They prevent fuel from sloshing violently during acceleration, braking, and cornering, which can affect vehicle handling and put stress on the tank.

Q7: How do I prevent fuel theft from my auxiliary tank?
A7: Look for tanks with lockable fuel caps and consider secure mounting solutions that make it difficult to remove the tank from the bed. Some pumps also have lockable nozzles.

Conclusion

Fuel tanks for pickup trucks are far more than just containers; they are key enablers for extended adventures, increased productivity, and enhanced self-reliance. Whether you opt for a convenient in-bed auxiliary tank or a seamlessly integrated larger replacement tank, the ability to carry more fuel fundamentally transforms your pickup’s capabilities. By carefully considering your needs, adhering to safety regulations, and choosing quality products, you can unlock a new level of freedom and efficiency, ensuring your truck is always ready for the long haul, no matter where the road (or lack thereof) takes you. Drive further, worry less, and maximize the potential of your pickup truck.