Ford Aeromax Truck Fuel Tanks

Frequently Asked Questions About Ford Aeromax Truck Fuel Tanks

What size fuel tanks fit my Ford Aeromax, and how do I determine the correct capacity?

Ford Aeromax trucks typically accommodate fuel tanks ranging from 50 to 150 gallons, depending on your model year and configuration. To determine the correct size, check your door jamb sticker for the original tank specifications, or measure your existing tank's dimensions (length x height x width). Most Aeromax models from 1988-1998 use either 23" or 25" diameter tanks. Keep in mind that dual tank setups are common, with typical configurations being 100-gallon tanks on each side or a 120-gallon primary with an 80-gallon secondary.

Are these fuel tanks compatible with both steel and aluminum step designs on my Aeromax?

Yes, our fuel tanks are designed to work with both steel and aluminum step configurations. However, you'll need to specify your step type when ordering, as the mounting brackets and strap positions differ. Steel steps typically require tanks with D-ring style mounts, while aluminum steps often use J-bolt configurations. If you're switching from steel to aluminum steps (or vice versa), you may need to purchase additional mounting hardware or modify your existing setup.

What's involved in installing a replacement fuel tank, and can I do it myself?

Installation typically takes 3-5 hours and requires basic mechanical skills. You'll need to drain the existing tank, disconnect fuel lines and sending unit wiring, remove the mounting straps, and carefully lower the old tank. Critical steps include properly torquing the new mounting straps (typically 35-45 ft-lbs), ensuring all fuel line connections are secure with new clamps, and verifying the sending unit float moves freely. We strongly recommend having a helper due to the tank's weight when filled. Always test for leaks before fully filling the new tank.

What's the difference between aluminum and steel fuel tanks, and which should I choose?

Aluminum tanks are lighter (reducing overall vehicle weight by 40-60 pounds), won't rust internally, and typically last 20+ years. However, they're more expensive and can be prone to corrosion at mounting points if not properly maintained. Steel tanks are more affordable and extremely durable against impact, but they're heavier and susceptible to internal rust if water accumulates. Most drivers choose aluminum for long-haul applications where weight matters, while steel remains popular for vocational trucks that face rougher conditions.

Do these fuel tanks come with sending units, straps, and mounting hardware?

Most replacement fuel tanks are sold as tank-only units, meaning sending units, straps, and mounting hardware are purchased separately. This allows you to reuse existing components if they're in good condition. Complete tank kits are available that include new straps, sending units, and all necessary hardware, typically adding $150-300 to the base tank price. When ordering, verify whether your existing sending unit is compatible with the new tank - some aftermarket tanks require specific sending unit depths that may differ from OEM specifications.