Fuel Tank

Common replacement tank sizes range from 26 gallons (stock equivalent) to 50+ gallons for long-range auxiliary tanks. Large tanks may require Cummins-style in-bed mounting or frame rail kits. Check your truck's spare tire location and rear crossmember clearance before ordering.

Most replacement tanks retain the factory sending unit mounts for plug-and-play wiring. If the tank has a different capacity, you may need to recalibrate the fuel gauge via a tuner or use an aftermarket fuel level sender for accurate readings.

OEM-style replacement tanks are usually aluminum or cross-linked polyethylene (LLDPE). Aluminum tanks offer better heat dissipation and durability on rocks. Poly tanks resist corrosion and are lighter but can be punctured by severe off-road impacts.

The in-tank lift pump usually does not need upgrading for a replacement tank of the same capacity. If installing a much larger tank or running dual pump setups, verify the pump's flow rate (GPH) matches your engine's demand, especially with aggressive delete tunes.

Fuel tank installation requires dropping the old tank (which is often full—drain or pump out first), disconnecting lines and wiring, and supporting the new tank during mount. Professional installation is recommended due to fuel handling safety and the weight of full tanks.

Yes. Many replacement tanks include pre-welded sump flanges. If your tank does not have one, external sumps bolt on with fuel-safe sealants and large clamps. Always ensure the sump sits above the lowest point in the tank for effective fuel pickup.

OEM fuel lines use quick-connect fittings that vary by truck model. Replacement tanks from reputable brands include the correct sender style and fitting sizes to match factory lines. Verify fitment by vehicle year, cab configuration, and bed length before ordering.

Quality aftermarket replacement tanks meet or exceed OE specifications and are DOT-compliant. Cheap imported tanks may not carry proper certification. Always check for a DOT compliance label on the tank before installation.

An in-bed auxiliary tank adds 30–60 gallons of extra range, ideal for long-haul or remote-area driving. It typically requires a transfer pump to move fuel to the main tank. Some systems auto-transfer when the main tank drops below a set level.

On a stock vehicle, a replacement tank alone does not affect emissions. However, if you install lift pumps, sump kits, or feed lines that alter the fuel system's emissions-certified components, it may interact with diesel exhaust fluid or emissions monitoring systems.