Aftermarket Fuel Tanks for Chevy Trucks | Capacity & Options
If you’re a Chevy truck owner looking to maximize your range and reduce fuel stops, aftermarket fuel tanks present a compelling upgrade. Whether you’re towing heavy loads cross-country or exploring remote trails, the stock fuel capacity on many Chevy trucks can feel limiting. This deep dive explores the various aftermarket fuel tank options available, focusing on capacity, materials, and key installation considerations. We’ll cut through the marketing jargon to give you the straight facts, helping you decide if this modification is the right fit for your needs and budget.
Why Consider an Aftermarket Fuel Tank for Your Chevy?
The primary reason truck owners seek out a replacement fuel tank is simple: more miles between fill-ups. The factory fuel tank on a Chevy Silverado 1500, for instance, typically ranges from 24 to 28 gallons. While sufficient for daily commuting, this capacity quickly becomes a bottleneck on long hauls or during off-grid adventures. An aftermarket fuel tank can dramatically increase this, with some models offering upwards of 50, 60, or even 90 gallons. Beyond sheer volume, these tanks are often constructed from more durable materials like polyethylene or aluminum, which are better resistant to corrosion and impact compared to some OEM steel tanks. For those who use their truck as a true tool, this upgrade is not a luxury but a necessity for improved efficiency and capability.
Comparing Fuel Tank Materials: Polyethylene vs. Aluminum
When selecting a replacement fuel tank, the material is a critical decision. The two most common options are cross-linked polyethylene and aluminum, each with distinct advantages.
- Polyethylene Tanks: Made from a high-density, durable plastic, these tanks are completely immune to rust. They are also lighter than their metal counterparts and can be molded into complex shapes to maximize space within a truck’s frame. Brands like Titan are renowned for their robust polyethylene designs. The material is also less prone to denting and can better absorb minor impacts without compromising integrity.
- Aluminum Tanks: Aluminum fuel tanks are prized for their strength and heat dissipation properties. They are extremely robust and are often the go-to choice for severe-duty applications or in environments where extreme physical abuse is a concern. While generally more expensive than polyethylene, they offer a classic, industrial-grade feel that many truck purists appreciate. However, they can be susceptible to galvanic corrosion if not properly installed and maintained.
Popular Aftermarket Fuel Tank Brands and Models
The market offers several reputable manufacturers specializing in Chevrolet truck fuel systems. Here’s a look at some of the top contenders.
Titan Fuel Tanks
Titan is a leader in the field, known for its high-capacity replacement tanks. They offer a direct replacement 50-gallon fuel tank for many late-model Chevy Silverado 2500/3500 trucks. This tank replaces the OEM unit without altering the vehicle’s ground clearance or exterior profile, a major plus for a clean, OEM+ look.
Transfer Flow Tanks
Transfer Flow provides a wide array of options, including in-bed auxiliary tanks and replacement main tanks. They are particularly well-regarded for their compliance with all EPA and CARB regulations, a crucial factor for legal operation. Their tanks are often DOT-approved, giving owners peace of mind.
S&B Tanks
S&B is another popular choice, especially for diesel truck owners. They manufacture both replacement and auxiliary tanks, with a focus on quality construction and a perfect fit. Their kits are typically comprehensive, including all necessary hardware for a straightforward installation.
Capacity and Options Comparison Table
To help visualize the differences, here’s a comparison of some popular aftermarket fuel tanks for Chevy trucks.
| Brand & Model | Capacity (Gallons) | Material | Vehicle Fitment (Example) | Type |
|---|---|---|---|---|
| Titan 50-Gallon Replacement | 50 | Polyethylene | Chevy Silverado 2500/3500 HD (2011-2019) | Main Tank Replacement |
| Transfer Flow 60-Gallon Auxiliary | 60 | Aluminum | Various Full-Size Trucks | In-Bed Auxiliary Tank |
| S&B 60-Gallon Replacement | 60 | Polyethylene | Chevy Silverado 1500 (2014-2018) | Main Tank Replacement |
Installation Insights and Professional Advice
Installing an aftermarket fuel tank is a significant job. While a seasoned DIY mechanic can tackle it, many owners opt for professional installation. The process involves safely dropping the old tank, which still contains fuel vapors, and correctly installing the new one along with all new fuel lines, sending units, and wiring as required. Mike Reynolds, a certified master technician with over 20 years of experience working on GM trucks, advises, “Always use a new fuel pump assembly or at a minimum, a new seal when installing a new tank. Reusing the old one is the most common cause of post-installation leaks. Also, ensure any auxiliary tank is plumbed correctly with a certified vented fill system to meet federal safety standards.” This expert insight underscores the importance of attention to detail for a safe and reliable outcome.
Legal and Safety Considerations You Can’t Ignore
Before purchasing any aftermarket fuel tank, it’s imperative to check its legal status. In the United States, the Environmental Protection Agency (EPA) and the California Air Resources Board (CARB) have strict regulations governing vehicle fuel systems. According to the EPA’s Code of Federal Regulations, fuel system components must be certified to control evaporative emissions. Using an uncertified tank can result in fines and prevent your vehicle from passing inspection. Reputable manufacturers like Transfer Flow clearly state which of their products are 50-state legal. Always verify this before buying.
Frequently Asked Questions
Q: Will a larger fuel tank improve my truck’s fuel economy?
A: Not directly. The tank itself doesn’t affect MPG. However, it can lead to more efficient trip planning by allowing you to bypass expensive fuel stations and maintain a consistent cruising speed for longer periods, which can indirectly save money.
Q: Can I install an aftermarket fuel tank myself?
A: It is possible for those with advanced mechanical skills, proper tools, and a safe way to lift and support the vehicle. However, due to the risks of working with fuel systems and the importance of proper emissions sealing, professional installation is highly recommended.
Q: How much does a new aftermarket fuel tank for a Chevy truck cost?
A: Costs vary widely. A basic replacement tank can start around $800, while a large, complex auxiliary system with all the necessary hardware and professional installation can easily exceed $2,500.
Q: Are there any downsides to a larger fuel tank?
A: The main downside is added weight, which can slightly reduce payload capacity. The initial cost is also significant. Furthermore, filling a 50+ gallon tank represents a substantial cash outlay at the pump, even if you do so less frequently.
Final Verdict on Aftermarket Chevy Truck Fuel Tanks
Upgrading to a larger aftermarket fuel tank is one of the most practical modifications for a serious Chevy truck owner. The freedom and convenience offered by a 600+ mile range are undeniable. When choosing a tank, prioritize quality manufacturers, correct legal certification, and professional installation. By investing in a well-made fuel tank from a brand like Titan or Transfer Flow, you’re not just buying a part—you’re enhancing the fundamental utility of your truck, turning it into a more capable and dependable partner for whatever journey lies ahead.
Sources and Further Reading
- EPA Regulations for Evaporative Emissions – U.S. Government Publishing Office.
- Titan Fuel Tanks Product Information – Manufacturer Website.
- Transfer Flow Product Information – Manufacturer Website.
