Ford F450-F550 Truck Fuel Tanks

Frequently Asked Questions About Ford F450-F550 Truck Fuel Tanks

What size fuel tank options are available for my Ford F450 or F550, and how do I know which one fits my truck?

Ford F450 and F550 trucks typically come with factory tank sizes ranging from 40 to 65 gallons, depending on your model year and cab configuration. For 2017-2024 models, regular cab trucks usually have a 40-gallon midship tank, while crew cab models can accommodate up to 65 gallons. To determine the correct replacement tank, check your door jamb sticker for your truck's specific configuration code, measure your existing tank dimensions (length x width x height), and verify the inlet/outlet port locations. Always cross-reference with your VIN to ensure proper fitment, as tank configurations can vary even within the same model year.

Are aftermarket fuel tanks made of steel or aluminum, and which material is better for my application?

Most replacement fuel tanks for F450-F550 trucks are available in both aluminized steel and aluminum options. Aluminized steel tanks are more affordable and offer good corrosion resistance for most applications, lasting 8-10 years under normal conditions. Aluminum tanks cost approximately 30-40% more but provide superior corrosion resistance, especially in salt-heavy environments, and can last 15+ years. If you operate in coastal areas, use road salt frequently, or haul corrosive materials, aluminum is worth the investment. For standard commercial use in moderate climates, aluminized steel provides excellent value.

Can I install a replacement fuel tank myself, or do I need special tools and expertise?

While fuel tank replacement is possible for experienced DIY mechanics, it requires specific safety precautions and tools. You'll need a transmission jack or fuel tank jack, proper ventilation, fire extinguisher, and fuel transfer equipment. The process typically takes 3-4 hours and involves disconnecting fuel lines, EVAP systems, and electrical connections for the fuel pump and sending unit. Many customers report difficulty with rusted mounting straps and hard-to-reach connections on lifted trucks. Professional installation typically costs $300-500 and ensures proper connections to avoid fuel leaks or check engine lights from improperly connected EVAP lines.

Will aftermarket fuel tanks work with my factory fuel gauge and emissions systems?

Quality aftermarket fuel tanks are designed to work with your factory fuel sending unit, fuel pump module, and EVAP (emissions) system. However, compatibility varies by manufacturer. Look for tanks that specifically state "direct OEM replacement" and include all necessary ports for your model year. 2011 and newer F450-F550 trucks have more complex EVAP systems that require exact port matching. Some customers report inaccurate fuel gauge readings with lower-quality tanks due to incorrect sending unit float arm geometry. Stick with reputable brands that guarantee OEM specifications to avoid these issues.

Do auxiliary or transfer tanks require additional modifications, and are they DOT approved?

Auxiliary fuel tanks and transfer tanks typically require a transfer pump system and additional plumbing to connect to your main tank. Most quality manufacturers offer DOT-approved tanks that meet FMVSS 301 standards for commercial use. Installation involves mounting the tank in your truck bed, running fuel lines with proper protection, and installing either a manual or electric transfer pump system. Electric systems with auto-transfer capabilities cost more but offer convenience. Check your state's commercial vehicle regulations, as some states have specific requirements for auxiliary tank installations on commercial vehicles over 10,000 pounds GVWR.