Regan Brown
Owning a Chevy Silverado 2500HD, GMC Sierra, or GMC 2500HD comes with the inconvenience of a small 26-gallon fuel tank. Many owners have expressed their desire for a larger fuel tank to avoid frequent stops at gas stations. While some have considered the GM 34-gallon tank as an option, others have opted for aftermarket solutions, such as the 52-gallon Titan fuel tank. Additionally, GM offers a second fuel tank behind the axle on 3500 chassis cab models, which could also fit the 2500. However, it is unclear if GM offered this as a factory option for any vehicle other than the chassis cab.
| Characteristics | Values |
|---|---|
| Fuel tank capacity | 26 gallons |
| Larger fuel tank capacity | 31 gallons, 34 gallons, 36 gallons, 52 gallons |
| Fuel tank replacement cost | $900 plus installation |
| Fuel tank replacement service provider | Aerosuds in Broomfield, Colorado |
| Vehicle models | Chevy Silverado 2500HD, GMC Sierra, GMC 2500HD, Chevy 2500 HD CrewCab 4x4 |
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What You'll Learn
GM offers a second fuel tank for 3500 chassis cabs, which can also fit the 2500HD
If you own a 2500HD, you may be considering your options for a larger fuel tank. While some 2500HD models have a 34-gallon stock fuel tank, others have a 26-gallon tank, which can be limiting for some users.
For those seeking even larger fuel tanks, aftermarket options are available. Titan Fuel Tanks offer a 60-gallon replacement fuel tank for 2020-2023 GM 2500HD and 3500HD pickups with Crew Cabs, Long Beds, and Duramax diesel engines. This tank is made of military-grade, cross-linked polymer (XLHDPE), which is tougher than steel and more durable than aluminum. It is designed as a direct fit, requiring no modifications, and ensures accurate fuel gauge readings.
Another aftermarket option is the 56-gallon replacement fuel tank for 2020-2021 GM 2500HD and 3500HD pickups with Crew Cabs, 6 1/2 ft. beds, and Duramax diesel engines. This extra-heavy-duty, midship replacement fuel tank provides additional fuel capacity for peace of mind during long drives or when driving in remote areas.
When considering larger fuel tanks, it is important to keep in mind the available space and clearances, especially for the shock absorber and exhaust pipe. Oversized fuel tanks often gain extra capacity by hanging lower than OEM fuel tanks, so ensuring proper measurements and fit is crucial.
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Aftermarket fuel tanks are available, but they are expensive
Aftermarket fuel tanks are available for your vehicle, but they are expensive. If you're looking to replace your 26-gallon fuel tank in your Chevy Silverado 2500HD with a larger capacity tank, you have a few options, but they may come at a cost.
One option is to purchase an aftermarket oversized fuel tank, which can provide increased capacity. These tanks can cost upwards of $900, plus installation, and gain capacity by hanging down lower than the OEM fuel tanks. This option should be relatively simple to install.
Another possibility is to explore GM's offerings. GM offers a second fuel tank option for 3500 chassis cab models, which can also fit the 2500HD. This OEM-style rear fuel tank is a more cost-effective solution than aftermarket tanks. However, it is unclear if GM offered this as a factory option for any models other than the chassis cab, and it does take up the space typically reserved for the spare tire.
Additionally, some later models of the Chevy Silverado 2500HD, such as the 2015 model year, came with a larger 34-gallon fuel tank. It may be possible to convert your current model to accommodate a larger tank, but it is essential to consider the available space underneath the vehicle.
Finally, you could consider a direct replacement option with a larger capacity, such as the 52-gallon Titan fuel tank, but this will also come at a significant cost.
While aftermarket fuel tanks can provide the desired increase in fuel capacity, they are indeed expensive. You may want to carefully consider your needs and explore all available options before making a decision.
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OEM-style rear fuel tanks are a cheaper option
If you're looking to increase the fuel capacity of your Chevy 2500HD, one option is to install an aftermarket oversized fuel tank. However, these tanks can be costly and may require modifications for a proper fit. As an alternative, OEM-style rear fuel tanks offer a more affordable solution.
OEM (Original Equipment Manufacturer) tanks are designed to meet the standards and specifications of the vehicle manufacturer. In the case of the Chevy 2500HD, GM offers a rear fuel tank option for the 3500 chassis cab model, which can also fit the 2500. This OEM-style rear fuel tank is a more cost-effective choice compared to aftermarket tanks, providing a larger fuel capacity without breaking the bank.
The OEM-style rear fuel tanks gain additional capacity by hanging lower than the standard OEM tanks. While they may not offer as much capacity as some aftermarket options, they provide a significant increase in fuel volume without the high costs associated with aftermarket oversized tanks.
For example, the stock fuel tank on the Chevy 2500HD is typically around 26 gallons, which may not be sufficient for longer trips or towing. By opting for an OEM-style rear fuel tank, you can increase the fuel capacity without spending a fortune. This option allows you to avoid frequent stops for refuelling, saving you time and money in the long run.
Additionally, OEM-style rear fuel tanks can be a safer choice. Carrying extra fuel in rear racks or auxiliary tanks can be hazardous. With the OEM-style rear fuel tank, you can increase your fuel capacity while maintaining a centred weight distribution on your truck. This enhances safety and improves the overall driving experience.
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$7.99
Oversized fuel tanks hang lower than OEM tanks
Installing an aftermarket oversized fuel tank in a Chevy 2500HD is possible, but there are a few things to consider. Firstly, oversized fuel tanks gain their increased capacity by hanging lower than the OEM fuel tanks. This means that while they are still higher than the axles and differentials, they do sit closer to the ground, which could be a problem when driving over rough terrain.
For example, one user with a Chevy Silverado 2500HD installed a Transfer Flow replacement tank with a capacity of 45 gallons. The new tank fit in roughly the same space as the original but hung down a little lower and was more rectangular in shape.
Another user with a Ford F250 installed a Titan fuel tank, which increased their fuel capacity from 26 gallons to 50 gallons with no modifications needed. Similarly, a user with a Ram 3500 reported that their S&B 65-gallon fuel tank hung down below the frame rail, preventing them from off-roading.
It is important to note that installing an aftermarket oversized fuel tank may affect fuel gauge accuracy and fuel economy due to the additional weight. Additionally, automatic fuel cutoffs may not work correctly with the new fill line, causing fuel to slosh out.
Before installing an aftermarket oversized fuel tank, it is recommended to research the specific make and model of your vehicle to ensure compatibility and be aware of any potential issues or modifications that may be required.
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Some people opt for a 52-gallon Titan fuel tank
Some people who own a Chevy 2500HD opt for a larger fuel tank, as the stock tank is relatively small at 26 gallons. One popular option is the Titan 7010201 52-gallon mid-ship replacement fuel tank. This tank provides additional fuel capacity, which can be useful when driving long distances or through remote areas, as well as giving you the ability to shop for lower fuel prices without having to fill up every time you pass a fuel station.
The Titan 52-gallon tank is made of corrosion-proof, high-density cross-linked polyethylene (XLHDPE), which is bonded molecularly and is at least 1/4 inch thick. It is designed to be tough and durable, with a lifetime warranty offered by the manufacturer. The tank is also relatively easy to install, as it reuses most of the stock components, including the existing sending unit.
One consideration when installing a larger fuel tank is the space available. The Titan 52-gallon tank takes advantage of all possible space underneath the vehicle, which can make it tougher to get into place. It is also important to consider the weight of the tank and the strength of the mounting straps and frame. Some users have expressed concerns about the lightweight mount on the Titan tank, questioning its durability compared to OEM supporting straps/frame.
Another factor to keep in mind is the accuracy of fuel gauge readings. Some users have reported issues with the fuel gauge reading inaccurately, especially when the vehicle is parked on an incline. Additionally, it may be necessary to install a lift pump and extra fuel line when installing the Titan 52-gallon tank.
Overall, the Titan 7010201 52-gallon mid-ship replacement fuel tank can be a good option for those seeking additional fuel capacity for their Chevy 2500HD. While it offers increased fuel range and peace of mind, there are also some considerations to keep in mind regarding installation, weight, and fuel gauge accuracy.
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Frequently asked questions
Yes, it is possible to upgrade to a larger fuel tank for your 2500HD. GM offers a second fuel tank behind the axle on 3500 chassis cab models, which can also fit the 2500. You can also opt for an aftermarket oversized tank, which can provide increased capacity by hanging lower than the OEM fuel tank.
There are both OEM and aftermarket options for larger fuel tanks. GM offers a 34-gallon tank, and aftermarket options include the 52-gallon Titan fuel tank, which is a direct replacement for the stock tank.
Upgrading to a larger fuel tank can provide increased fuel capacity, reducing the frequency of fuel stops. This can be particularly advantageous when towing or boondocking, as it extends the range of your vehicle.
