Katerina Swanson
In-cab fuel tanks have been a feature of many trucks and pickups, including those made by Ford and GM. While some people prefer fuel tanks to be located inside the cab, others worry about the safety implications, particularly in the event of a crash. Some people have expressed concerns that an electrical malfunction could ignite vapors in the tank. While carmakers and the authorities have defended the safety of their vehicles, critics have argued that the use of dual tanks in a vulnerable location significantly increases the danger.
| Characteristics | Values |
|---|---|
| Cab-mounted fuel tanks available until | 1979 |
| Example models with cab-mounted tanks | 1976 F-250 4x4, 1978 crew cab, 1975 F250 4x4 HiBoy, 1978 F-250 |
| Concerns | Risk of fire, electrical malfunction, accidents |
| Safety comparison with external tanks | Varied opinions |
| Official stance | No recalls, met fuel-system safety standards |
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What You'll Learn
Fuel tank rupture during accidents
One well-known example of fuel tank rupture is the Ford Pinto case, where many people lost their lives when their vehicles were rear-ended, causing gas tank ruptures, explosions, and fires. Similarly, Jeep recalled over 1.5 million cars due to the improper placement of gas tanks, an issue that could have been easily rectified but instead claimed 50 lives first. These incidents highlight the critical nature of fuel tank placement and the potential consequences when manufacturers neglect safety standards.
In modern vehicles, fuel tanks are typically made of plastic (HDPE), which has lower fracture toughness compared to steel or aluminum. To ensure safety, manufacturers must place fuel tanks in areas immune to deformation or puncture, typically just ahead of the rear axle. Additionally, shields should be in place to absorb most of the impact and minimise the risk of rupture.
While older vehicles may have fuel tanks located inside the cab, this setup is no longer common due to safety concerns. In the event of an accident, a ruptured fuel tank inside the cab could have catastrophic consequences, with fuel vapors igniting and causing an explosion or fire within the occupant compartment.
It is important to recognise that fuel tank ruptures during accidents can have severe legal implications as well. Product liability laws hold manufacturers, designers, suppliers, distributors, and retailers accountable for their negligence regarding unsafe products. If a fuel tank is found to be defective or improperly placed, resulting in injuries or fatalities, those responsible can be legally liable for property damages, medical bills, lost wages, and pain and suffering.
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Electrical malfunction
In-cab fuel tanks have been known to cause worry among vehicle owners due to the potential for electrical issues to cause an explosion. One concern is that an electrical malfunction could send 12 volts into the fuel sender, igniting the vapours in the tank. This could result in a dangerous situation for the occupants of the vehicle. However, others argue that the 12-volt current is regulated and averages around 5 volts, reducing the risk of ignition.
Additionally, fuel tanks contain a mixture of fuel and oxygen, and it is well known that spark plus fuel and oxygen can lead to an explosion. While gasoline has high resistance and requires a significant amount of oxygen to ignite, there is still a possibility of sparking occurring within the tank. Sliding contacts over open coils can produce sparks, and fuel senders and level sending units may also contribute to this issue.
To mitigate these risks, certain precautions must be taken during the installation of aboveground fuel tanks, which are often used for storing combustible liquids and petroleum products. The National Environment Policy Act (NFPA) provides clear instructions and guidelines for users to ensure safety. These guidelines cover various electrical components such as wiring methods, connections, transformers, and more. Aboveground tanks should also be installed at a safe distance from buildings and electrical equipment, and proper wiring methods should be utilised to prevent accidents.
While the risk of electrical malfunction in in-cab fuel tanks is a valid concern, it is important to follow safety guidelines and regulations to minimise potential hazards. Proper installation, maintenance, and awareness of electrical requirements can help reduce the chances of an accident occurring.
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Fire risk
In-cab fuel tanks have been described as "the most dangerous vehicles, from a fire risk standpoint, ever produced". The primary concern with in-cab fuel tanks is the risk of fire in the event of a crash. In the case of a violent crash, any vehicle can leak fuel and catch fire. However, the presence of fuel tanks in the cab of a vehicle increases the danger to the occupants.
In the past, some trucks had fuel tanks located inside the cab, behind the seat. This design meant that drivers could hear the sound of sloshing fuel as they drove. Moving the tanks outside the frame was considered a safety improvement. Despite this, some drivers express a preference for in-cab tanks, believing them to be safer than external tanks, which could be vulnerable to ruptures in a collision.
The dangers of side-saddle fuel tanks were well-known when they were introduced. A 1966 memo from Dodge stated that side-mounted tanks were "not acceptable", as any side impact would likely result in tank leakage. This was echoed by a GM engineer, who acknowledged that mounting a fuel tank on the front bumper would be a worse design choice.
Despite this, GM pickups with side-saddle tanks were produced for many years, and the company has defended their safety record, stating that the trucks met fuel-system safety standards at the time of production. However, internal documents from as early as 1964 show that GM was aware of the risks associated with externally mounted fuel tanks, and the company has settled hundreds of lawsuits and claims by fire victims and their families, paying out over $500 million.
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Design flaws
In-cab fuel tanks have been described as dangerous by some users, who worry about the possibility of an electrical malfunction sending 12 volts into the fuel sender and igniting vapors in the tank. In the event of a violent crash, fuel can leak and catch fire, and in-cab tanks are particularly vulnerable to this. This is because, in a side impact, the probability of tank leakage is extremely high. This is supported by FARS data from 1977, which showed a higher risk of fire-related deaths in GM pickups with side-mounted tanks than in rival Ford and Dodge models.
Some users have expressed that they feel safer with an in-cab tank, as it protects the fuel tank with the frame, comparing it to "taking a human heart and putting it outside the chest. The heart is protected by the ribs, and the fuel tank should be protected by the frame".
Carmakers and federal authorities have been aware for 20 years that a popular truck line is prone to bursting into flames. Despite this, officials have defended the trucks, stating that they met fuel-system safety standards when they were produced.
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Safety standards
In the United States, the National Highway Traffic Safety Administration (NHTSA) plays a crucial role in investigating and addressing safety defects in vehicles, including fuel tank-related issues. In 1994, NHTSA settled an investigation into alleged safety defects in certain GM pickup trucks with fuel tanks mounted outside the frame rails. This settlement included funding for research on reducing post-crash fires and improving engine component fire safety.
To enhance fuel system integrity, safety standards focus on several key aspects. One critical measure is to prevent fuel siphoning and reduce the risk of fuel tank failure during collisions. This includes implementing fuel pump shut-off switches that activate in various crash scenarios. Testing and examining vehicle components, such as fuel lines, fuel filler necks, caps, and inertia switches, are also crucial to ensure their integrity.
For vehicles with fuel tanks located inside the cab, specific safety considerations come into play. One concern is the potential for electrical malfunctions, where a high-voltage current could ignite vapors in the tank. To mitigate this risk, voltage regulators are used to maintain a safe voltage level. Additionally, the placement of the fuel tank within the cab should be carefully designed to minimize the risk of rupture during an accident, as a ruptured tank could have severe consequences for the occupants.
In terms of regulatory requirements, organizations like the Occupational Safety and Health Administration (OSHA) provide guidelines for portable fuel tank storage and fuel transfer on construction sites. These guidelines emphasize the use of approved containers specifically designed for the type of fuel being stored. Plastic containers are generally discouraged due to their inability to meet the requirements of a "safety can." Proper signage and labelling are also mandatory, including content stickers, NFPA diamond placards, and "FLAMMABLE – KEEP FIRE AND FLAME AWAY" signs. Additionally, fire extinguishers must be placed at a specified distance from the fuel tanks, and visible "No Smoking" signs must be posted to eliminate ignition sources.
For above-ground fuel tanks, safety requirements include the preference for double-walled tanks over single-wall tanks. Double-walled tanks provide an extra layer of protection against leaks, with the outer tank safeguarding the inner tank from external factors like rain and punctures. Regular inspections of containment devices are also necessary to identify and address issues like cracks, punctures, and leaks. Local regulations, such as those from the Environmental Protection Agency (EPA) and the Department of Natural Resources (DNR), must also be considered to ensure compliance.
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Frequently asked questions
In-cab fuel tanks are considered dangerous because they increase the risk of fire-related deaths in the event of a violent crash.
In the event of a crash, an in-cab fuel tank could rupture, spilling fuel into the cab and increasing the risk of fire.
Some people prefer in-cab fuel tanks because they free up space in the truck bed and they no longer have to listen to the sound of sloshing fuel.
Yes, side-mounted or rear-mounted fuel tanks are alternatives to in-cab fuel tanks. However, side-mounted tanks have been described as "not acceptable" by some manufacturers due to the increased probability of tank leakage in the event of a side impact.
