Frequently Asked Questions About Ford F650-F750 Truck Diesel Fuel Tanks

What size fuel tanks are available for Ford F650-F750 trucks, and how do I choose the right capacity?

Ford F650-F750 diesel fuel tanks typically range from 50 to 150 gallons, with 65-gallon and 100-gallon options being most common. To choose the right capacity, consider your typical route distances, payload requirements, and mounting space. Larger tanks reduce refueling stops but add weight and may require frame rail modifications. Most vocational trucks benefit from 100-gallon tanks, while regional haulers often prefer 150-gallon setups for extended range.

Will aftermarket fuel tanks fit my specific F650-F750 model year, and what are the compatibility concerns?

Fuel tank compatibility varies significantly between model years, particularly with the 2016+ redesign featuring different frame dimensions and mounting points. Pre-2015 models typically use strap-mount systems, while 2016-2023 models may require bracket modifications. Always verify your truck's wheelbase, frame rail spacing, and existing tank configuration before ordering. Crew cab models often have different tank placement requirements than regular cab versions.

What material options are available, and which is best for durability and weight?

Aluminum and steel are the primary options for F650-F750 fuel tanks. Aluminum tanks weigh 40-50% less than steel equivalents and resist corrosion better, making them ideal for weight-sensitive applications and coastal environments. Steel tanks cost less initially and handle impact damage better but require protective coatings to prevent rust. Most fleet operators prefer aluminum for long-term value despite the higher upfront cost.

Can I install a replacement fuel tank myself, or do I need professional installation?

While experienced mechanics can install fuel tanks, professional installation is strongly recommended due to safety and regulatory requirements. Installation involves fuel system disconnection, potential frame drilling, proper grounding, and emissions system integration. DOT regulations require specific mounting hardware torque specifications and fuel line routing. Most installations take 4-6 hours and may require DEF tank relocation on newer models.

Do aftermarket fuel tanks affect my truck's warranty or DOT compliance?

Quality aftermarket fuel tanks that meet FMVSS 301 standards maintain DOT compliance when properly installed. However, improper installation or non-compliant tanks can void powertrain warranties and fail inspections. Ensure any replacement tank includes proper venting, rollover protection, and meets your state's specific requirements. Keep installation documentation and certification papers for warranty claims and compliance verification.