Overlander’s Guide to Auxiliary and Replacement Fuel Tanks

Auxiliary and Replacement Tanks to Fuel Future Adventures

No matter if you’re adventuring in the remote wilderness or dashing across the country with your family, having a fuel tank boasting long-range fuel capability is important. It minimizes fuel stops, and it’ll get you to your end destination more quickly.

However, if you’re tired of constant fill-ups and want to expand your vehicle’s capacity, adding an extended-range fuel tank could be the perfect answer. Some vehicles, such as Toyota Tundras, have stock tanks ranging from 26.4 to 38 gallons, but many other automakers offer much less than that.

Case in point: the 1991 right-hand-drive Mitsubishi Pajero my husband and I own. Our minuscule OE bladder offered 250 miles per tank—at best. Our 1994 Mitsubishi Delica Space Gear’s tank wasn’t much better … not good when you’re spending remote nights in the middle of nowhere or running a 5,120-mile-long Arctic road rally in the dead of winter.

We hated dealing with jerry cans. While they do work, they can often be messy, smelly, and lead to frustration. Plastic containers can discolor or leak; metal ones can dent or rust … not to mention the constant venting to release pressure built up within them. We wanted a better solution for our travel-fueled, long-range woes.

What are the alternatives? Installing an auxiliary or replacement fuel tank could double your adventuremobile’s capacity, as opposed to that of its OE holder—giving you endless opportunities to explore Mother Nature. Not only do they offer an increased range, but they’re also safer and more secure—no more jerry can “eye candy” for thieves to steal.

Large-capacity fuel tanks also come in handy when foul weather hits, giving you peace of mind should a wildfire break out or floods encroach on your surroundings. Lastly, auxiliary or replacement tanks can cut fuel costs by allowing you to fill up when you want (such as when cheaper fuel is nearby) and not necessarily when you have to.

Extended-Range Options

We spoke with representatives from two companies that specialize in making long-range fuel tanks.

Idaho-based Long Range America (LRAM) is the exclusive U.S. distributor that imports replacement and auxiliary long-range tanks from Long Range Automotive (LRA), based in Australia. Founded in 2015, LRAM has imported these tanks for a variety of vehicles, including models such as Lexus GXs, Toyota Tacomas, Mercedes Sprinter vans, and even Mitsubishi Delicas.

Installing an auxiliary or replacement fuel tank could double your adventuremobile’s capacity, as opposed to that of its OE holder—giving you endless opportunities to explore Mother Nature.

American-made TITAN Fuel Tanks manufactures aftermarket high-capacity gasoline and diesel tanks from military-grade polymer. From midship direct replacement tanks to spare tire carrier aux systems and after-axle or in-bed transfer tanks, TITAN has featured diesel and gasoline variants for popular off-road vehicles and UTVs since 2003.

Auxiliary or Add-In Awesomeness

An auxiliary tank, otherwise known as a “transfer” or “add-in” tank, is an extra fuel tank that works in tandem with a stock OE fuel tank. Most of the time, an aux tank will be mounted beneath a vehicle—as with our Pajero—but it can also sit on top of one if it’s a truck bed transfer tank, such as models offered by TITAN. Both LRA and TITAN auxiliary tanks offer a unique opportunity to “fill on the go.” With a simple press of a button, the add-in tank will start transferring fuel into the main tank, no matter if your vehicle is touring through town, tackling trails, or sitting silently in a parking lot.

An add-in or transfer tank taps into a vehicle’s main OE tank is connected to its fuel system and has a transfer pump that initiates fuel transfers after a user presses the system’s button. Both LRA and TITAN aux tanks boast an in-cabin fuel gauge with a start/stop button that can be mounted in various locations; however, other manufacturers could vary. We had the Pajero’s gauge that monitored the LRA aux tank mounted in an empty knock-out switch plate on the vehicle’s dashboard.

Aux Tank Details

Not only do auxiliary tanks significantly increase capacity, but they also have a separate fill neck (aside from the OE opening). Behind the Pajero’s fuel door are two holes: one for the stock tank and another for its aux add-in counterpart. Once the puny Pajero bladder was upgraded with the extra tank, it boasted a robust, 500-plus miles of range.

Aux, add-in or transfer tanks come in many shapes and sizes. They increase the range to nearly double the OE capacity. Check range statistics on the tank you want before purchasing it. If you know your way around your vehicle, are skilled with wrenches and have appropriate tools, you might be able to install an auxiliary tank yourself. About a quarter of TITAN customers install their own tanks. Alternatively, it could be installed by a trained professional. LRAM requires this for most of its models.

Replacement Tank Readiness

Another option to up your range is a replacement fuel tank—out with the old, and in with the new. Similar to aux tanks, replacement tanks can provide up to twice the range capacity when compared to stock tanks. Again, check the range statistics of the tank you’re interested in before purchasing it.

Wanderlust Overland, an approved LRA install shop, recently upgraded the Delica van with an LRA replacement tank. Installation was a snap and took just a few hours. Unlike the Pajero aux tank, the Delica tank doesn’t showcase an extra fill opening or interior fuel gauge and switch. Instead, it uses the stock fuel gauge, light and OE fill neck. (Note: The van’s gauge drops slowly now because we doubled our capacity to an impressive 33 gallons. This gives us approximately 600 miles with one fill.)

California Emission Standards

LRAM sells high-quality, 2mm aluminized steel tanks throughout the United States, Canada, and Mexico. It doesn’t currently sell or ship tanks for installation for California-registered vehicles.

“The state requires an executive exemption from the California Air Resources Board (CARB) for aftermarket replacements or add-in accessories that might affect fuel storage or emission systems,” explains Ward Harris, co-owner of the company. “We’re working toward an exemption for each of our more popular kits to satisfy the state’s reasonable interest in compliance with new vehicle evaporative emission standards.”

Aux, add-in or transfer tanks come in many shapes and sizes. Even so, once installed, they could up the range to nearly double the OE capacity.

Types of Tanks

LRAM fits a wide variety of gasoline and diesel adventure rigs for recreational, commercial, and specialty uses. They boast a 36-month warranty on tank parts and materials—with no mileage cap.

Conversely, TITAN Fuel Tanks sells replacement polymer-based tanks for diesel and gasoline vehicles in the state. In addition, the company backs its polymer tanks with an unlimited lifetime warranty.

“All of our tanks are 50-states-legal; they meet and exceed all EPA and CARB regulations,” points out Mike DeFord, marketing manager of the company.

(CARB is updating its procedures about how the application and review process might change. Time will tell if Californians will get additional long-range tank options in the future.)

Long-Range Longevity

We’ve never looked back since we installed an LRA Pajero aux tank for the Alcan 5000 Rally. A simple push of a button fueled us up. Others filled OE tanks with jerry cans in temps of -20 (F) and below.

The aux tank worked so well that we opted for a long-range LRA replacement tank for the Delica van. This doubled our mileage for future #vanlife adventures.

“Our tank works so well, you don’t even know it’s there!” exclaims Andy Lilienthal. “Having a long-range tank also ‘spoils’ you for vehicles with regular tanks. Now, we stop more for bathroom breaks than fill-ups. I wish LRAM could increase my bladder size!”

FREQUENTLY ASKED QUESTIONS

What are some specific replacement fuel tank options available for different truck models?

Replacement Fuel Tank Options for Various Truck Models

For Ram Cab Chassis:

1. 40 Gallon Option:
   This tank is ideal for replacing the midship or aft axle fuel tank on models with a 60″ cab-to-axle (CA) measurement. It’s a robust option for those needing reliable fuel storage in their Ram setups.
2. 50 Gallon Options:
   • 84″ CA: Perfect for vehicles measuring 84″ from the cab to the axle. This larger capacity helps extend driving range, ensuring fewer stops during long hauls.
   • 108″-120″ CA: Catering to the largest measurements between cab and axle, this tank significantly increases your fuel volume capacity.

For Ford Vehicles:

1. 45 Gallon Ford Transit 350 Van:
   Enhance your Ford Transit 350 Van’s travel range with this substantial fuel tank. This upgrade is ideal for owners needing additional fuel storage without constant refueling.
2. 58 Gallon Fuel Tanks:
   • Gasoline Version: This is a significant upgrade compatible across the states, providing a legal and safe solution for maximizing fuel capacity.
   • Diesel Version: Engineered for durability and long-distance travel, this replacement tank is designed to cater to diesel variants, making it a serious contender for those who travel extensively.

For Toyota Tundra:

1. 46 Gallon Option:
   Tailored for the Toyota Tundra, this replacement tank nearly doubles your driving range. It’s a practical solution for Tundra owners aiming to enjoy extended road trips with fewer fuel stops.

These replacement tanks offer substantial upgrades for drivers who frequently hit the highway or require more fuel for their demanding schedules. With options available for different makes and models, these fuel tanks cater to a wide array of vehicle needs.

How do steel replacement fuel tanks compare to plastic tanks in terms of durability and driving stability?

When evaluating the durability and driving stability of steel replacement fuel tanks versus plastic alternatives, several factors come into play.

Durability

Steel fuel tanks, constructed from 12- and 14-gauge aluminized steel, offer a level of toughness that plastic tanks simply can’t match. This robust material enhances the tank’s ability to withstand various environmental conditions, including temperature fluctuations and impact, ensuring a longer lifespan and better protection for your vehicle’s fuel system.

Driving Stability

In terms of driving stability, steel tanks have an edge due to the inclusion of multiple baffles. These internal structures effectively minimize fuel movement within the tank. As you accelerate, brake, or corner, the fuel is contained more securely, leading to improved vehicle stability and safety.

Comparison Overview

• Material Strength: Steel provides superior strength and resistance to damage compared to plastic.
• Stability Features: Baffling in steel tanks reduces sloshing, enhancing driving performance and safety.
• Longevity: Steel tanks generally outlast their plastic counterparts, making them a cost-effective choice over the long run.

In summary, while both steel and plastic tanks serve the basic purpose of fuel storage, steel options are the frontrunners for those prioritizing durability and a stable driving experience.

How does the fuel capacity of replacement fuel tanks vary among different vehicle models?

Similar to aux tanks, replacement tanks can provide up to twice the range capacity when compared to stock tanks. Again, check the range statistics of the tank you’re interested in before purchasing it.

Replacement fuel tanks offer a tailored solution for different vehicle models, ensuring that you can extend your journey without frequent refueling. Here’s how the capacity varies among popular models:

• 40 Gallon Ram Cab Chassis Midship Replacement Tank: Ideal for a 60″ CA Ram cab chassis, this tank significantly boosts your fuel storage capacity, making it perfect for longer hauls.
• 45 Gallon Ford Transit 350 Van Midship Replacement Fuel Tank: Designed specifically for the Ford Transit 350 Van, this tank enables you to cover more miles with fewer stops.
• 46 Gallon Toyota Tundra Midship Replacement Fuel Tank: Nearly double your driving range with this high-capacity option for Toyota Tundra owners, allowing for extended adventures.
• 50 Gallon Ram Cab Chassis Midship Replacement Tank: Available for both 84″ and 108″-120″ CA Ram cab chassis models, these tanks offer impressive capacity boosts for those who need it most.
• 58 Gallon Ford Midship Replacement Fuel Tank: Whether for gasoline or diesel, these tanks are engineered to maximize fuel storage, ensuring compliance and performance across all states.

When considering a replacement fuel tank, take note of your specific vehicle model and desired range capacity to choose the best fit for your needs.

Are there variations within the same vehicle model for different configurations?

Yes, there are variations such as the 50-gallon tanks available for different configurations of the Ram cab chassis, including 84″, 108″, and 120″ CA options.

Which specific vehicles are compatible with these replacement fuel tanks?

Models compatible with these tanks include the Ram cab chassis (with different configurations), Ford Transit 350 Van, and Toyota Tundra.

What is the price of each replacement fuel tank?

Prices vary depending on the tank, with costs ranging from approximately $2,137 to $2,730.

What are the part numbers for these replacement fuel tanks?

Each tank has a unique part number, such as 0800115805 for a 40-gallon tank and 0800117272 for a 45-gallon tank, among others.

What are the specific fuel capacities available for different vehicle models?

The available fuel capacities range from 40 to 58 gallons, catering to vehicles like the Ram cab chassis, Ford Transit 350 Van, and Toyota Tundra.

What is the advantage of having a 50-state legal gasoline replacement fuel tank?

“All of our tanks are 50-states-legal; they meet and exceed all EPA and CARB regulations,” points out Mike DeFord, marketing manager of the company. This means that regardless of where you drive across the country, your fuel tank is compliant with state regulations, ensuring peace of mind and hassle-free travel.

Benefits of 50-State Legal Tanks

1. Uniform Compliance: With these tanks, you’re not just meeting federal standards but also satisfying every state’s unique requirements, a crucial factor for those who frequently travel or relocate.
2. Avoid Penalties: Stay clear of potential fines or complications that might arise from using non-compliant equipment in certain states.
3. Enhanced Resale Value: Vehicles equipped with 50-state legal tanks often retain better value since they appeal to a broader market.

By choosing a tank that’s accepted nationwide, you gain the freedom to drive without worrying about legal constraints, ensuring a smoother journey wherever the road may lead.

Who offers these tanks?

The company providing these tanks is Transfer Flow.

Which vehicles are these tanks available for?

These tanks are designed for a specific range of vehicles, referred to as “select vehicles.”

Can replacement fuel tanks be installed easily with included parts and hardware?

Wanderlust Overland, an approved LRA install shop, recently upgraded the Delica van with an LRA replacement tank. Installation was a snap and took just a few hours. The fuel tanks are powder-coated black for a durable finish and come equipped with all parts needed for installation, including straps and mounting hardware. This ensures that whether you’re a seasoned mechanic or a DIY enthusiast, you’ll have everything at your fingertips to get the job done.

Unlike the Pajero aux tank, the Delica tank doesn’t showcase an extra fill opening or interior fuel gauge and switch. Instead, it uses the stock fuel gauge, light, and OE fill neck. This seamless integration means you maintain the clean, original look of your dashboard while benefiting from increased fuel capacity.

With all components included, upgrading your vehicle becomes a straightforward process, making it easier than ever to prepare for your next adventure. Whether you’re hitting the open road or exploring off-the-beaten-path destinations, this setup supports your wanderlust with efficiency and style.

Is there any mention of installation hardware?

Yes, installation hardware is included, facilitating a straightforward setup process.

What kind of finish do the fuel tanks have?

The tanks are finished with a black powder coating, which ensures durability.

Are all necessary parts for installation included with the fuel tanks?

Yes, the fuel tanks come with everything needed for installation, such as the necessary straps and mounting components.

What materials are used in the construction of durable replacement fuel tanks?

TITAN Fuel Tanks manufactures aftermarket high-capacity gasoline and diesel tanks from military-grade polymer. This advanced material is designed for resilience, offering exceptional impact resistance and longevity suitable for demanding environments. Unlike traditional plastic tanks, which can be prone to wear and degradation, TITAN’s military-grade polymer ensures reliable performance under extreme conditions.

For those seeking even greater durability, our tanks are constructed using robust materials that enhance their strength. Specifically, we utilize 12- and 14-gauge aluminized steel, known for its superior durability and resistance to corrosion. This combination of materials not only extends the lifespan of your fuel tank but also provides unmatched protection against the elements.

By choosing tanks crafted from these high-quality materials, you’re investing in a solution that prioritizes both performance and longevity. Whether you’re navigating rugged terrains or enduring harsh weather, these tanks are engineered to withstand the challenges and keep your vehicle running smoothly.

What are the properties or benefits of the chosen material?

Aluminized steel provides significant durability and strength, which are crucial for the reliable and safe storage of fuel, particularly when replacing existing tanks.

How does the material choice compare to other common materials?

Unlike plastic, aluminized steel offers enhanced strength and durability, making it a superior choice for long-lasting fuel tanks.

What specific type of metal is used in the construction of the tanks?

The tanks are constructed from aluminized steel, specifically in 12-gauge and 14-gauge thicknesses, ensuring robust and reliable performance.

What warranty is provided with the purchase of a replacement fuel tank system?

“Conversely, TITAN Fuel Tanks sells replacement polymer-based tanks for diesel and gasoline vehicles in the state. These innovative tanks offer durability and performance, ensuring peace of mind for drivers. In addition, the company backs its polymer tanks with an unlimited lifetime warranty, demonstrating their confidence in the product’s longevity and reliability.

For those preferring traditional materials, our replacement fuel tank systems are crafted from the highest quality American-made steel. Each tank is proudly made in the USA and comes with a robust 6-year, unlimited-mile warranty. This extensive coverage guarantees that your investment is protected, allowing you to drive with assurance for years to come.

Whether choosing polymer for its lightweight and corrosion-resistant properties or steel for its classic strength, you’ll find a warranty that matches the durability and quality of the tank you select.”

What materials are used in the manufacturing process?

The tanks are crafted from high-quality steel produced in America.

Where are the fuel tank systems manufactured?

The systems are manufactured in the United States.

What type of warranty coverage is provided?

The warranty offers unlimited mileage coverage.

What is the duration of the warranty?

The warranty lasts for six years.