Frequently Asked Questions About Ford F450-F550 Truck Diesel Fuel Tanks
What tank sizes are available for my Ford F450 or F550, and how do I determine which one fits my truck?
Most aftermarket diesel fuel tanks for F450-F550 trucks range from 38 to 65 gallons, with 40-gallon and 55-gallon options being the most common. To determine the correct size, check your truck's wheelbase and bed configuration. Regular cab models with 8-foot beds typically accommodate larger tanks, while crew cab models may require mid-mount or side-mount configurations. Always verify your specific year model (2011-2016 vs 2017-2023) as mounting points changed with the aluminum body redesign in 2017.
Will I need to modify my truck or fuel system to install an aftermarket diesel tank?
Most quality aftermarket tanks are designed as direct replacements requiring no drilling or cutting. However, you may need to relocate or extend fuel lines, especially when upgrading to a larger capacity tank. Some installations require a new fuel pump module or sending unit, which typically adds $200-400 to your project cost. For 2017+ models, verify that the tank includes updated mounting brackets that work with the aluminum frame rails.
What's the difference between steel and aluminum diesel fuel tanks for my F450/F550?
Steel tanks are typically powder-coated or aluminized and cost 20-30% less than aluminum options. They work well for most applications but can develop rust after 5-7 years in salt-heavy regions. Aluminum tanks resist corrosion better and weigh about 40% less, making them ideal for weight-conscious applications or coastal areas. Both materials meet DOT standards, but aluminum tanks generally carry longer warranties (5-10 years vs 2-3 years for steel).
How long does installation typically take, and can I do it myself?
Professional installation usually takes 3-5 hours depending on your truck's configuration. DIY installation is possible if you have basic mechanical skills, a transmission jack or tank jack, and a helper. The most challenging aspects are safely lowering the old tank when full and properly connecting the fuel pump wiring harness. Many customers report spending 5-8 hours on their first DIY installation. Always disconnect the battery and relieve fuel system pressure before starting.
Are aftermarket tanks compatible with factory DEF systems and fuel gauges?
Quality aftermarket diesel tanks maintain full compatibility with your truck's DEF system, as these are separate components. Fuel gauge compatibility depends on whether the tank includes the correct ohm-range sending unit for your model year. Pre-2017 F450/F550 trucks use a different sending unit specification than 2017+ models. Some universal tanks require purchasing a year-specific sending unit separately ($75-150) to ensure accurate fuel level readings on your dashboard.
