Rajan Wilcox
Owning a truck with a large fuel tank has its perks. For instance, you can fill up where gas is cheap and avoid frequent fuel stops. However, it can also be a nuisance when you fill up your tank and then see gas prices drop soon after. Owners of the Chevy Silverado 2500HD often complain about the stock 26-gallon fuel tank, which only lets them drive up to 300 miles. Some have opted for a 52-gallon Titan fuel tank, while others have gone for a 45-gallon Transfer Flow tank. If you're considering upgrading your fuel tank, it's important to weigh the benefits of having a larger tank against the costs and potential challenges of installation.
| Characteristics | Values |
|---|---|
| Stock fuel tank capacity | 26 gallons |
| Larger fuel tank options | 34 gallons, 42 gallons, 45 gallons, 52 gallons, 55 gallons, 67 gallons |
| Fuel tank material | Plastic, steel |
| Fuel type | Gas, diesel |
| Vehicle make and model | Chevy Silverado, GMC Sierra, GMC 2500HD, Chevy 2500HD, Chevy 3500 |
| Vehicle bed type | Extended cab, short box, long bed |
| Fuel tank replacement cost | $900 plus installation |
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What You'll Learn
- Owners of Chevy 2500HD trucks have considered replacing the standard 26-gallon fuel tank
- The Titan 52-gallon tank is a popular replacement option, but some worry it's only for diesel
- Some owners opt for a 45-gallon Transfer Flow tank, which fits standard bed LBZ
- GM offers a second fuel tank behind the axle on 3500 chassis cab models, which may also fit the 2500
- One owner replaced their 39-gallon tank with a 67-gallon Titan tank for a trip to Alaska, reducing fuel stress
Owners of Chevy 2500HD trucks have considered replacing the standard 26-gallon fuel tank
Some owners have opted for a 45-gallon Transfer Flow frame-mounted gas tank, which provides a greater range and the ability to fill up where gas is cheaper. Others have chosen to install a 52-gallon Titan tank, although this option is only suitable for diesel gas. Owners have also mentioned the Aero 55-gallon all-steel tank as a viable replacement, which can be installed in around five hours and makes use of the factory sending unit.
For those with the long-bed model Chevy 2500HD, a larger 35-gallon tank is available. This option provides a greater fuel capacity while still using the existing space in the truck. Additionally, some Chevy 2500HD models have been found to have a 34-gallon stock fuel tank, which may be an option for older trucks as well.
While some owners have successfully replaced their fuel tanks with larger ones, others have opted to keep the standard tank and instead carry extra fuel in 5-gallon jerry cans. This provides a temporary solution for those who need the extra fuel for camping or towing without making any permanent modifications to the vehicle.
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The Titan 52-gallon tank is a popular replacement option, but some worry it's only for diesel
The Titan 52-gallon tank is a popular replacement option for those looking to increase the fuel capacity of their vehicles. It offers a significant increase in fuel capacity compared to the standard 26-gallon tank found in some Chevy Silverado and GMC Sierra trucks.
However, there is some confusion and concern among potential buyers about its compatibility with diesel and gasoline engines. Some sources indicate that the Titan 52-gallon tank is specifically designed for diesel engines, while others suggest that it can be used with gasoline trucks as well.
For example, one user on a forum mentions that they came across the Titan 52-gallon tank as a replacement option but were unsure if it was only suitable for diesel fuel. They state, "They will replace the 26-gallon tank with 52! But they say it's only good for diesel gas? Not sure why." This uncertainty is understandable, as it is essential to ensure that any modifications or replacements are compatible with the vehicle's specifications.
On the other hand, there are users who have installed the Titan 52-gallon tank in their Chevy Silverado and GMC Sierra trucks, which are known to have gasoline engines. For instance, a user mentions installing the Titan tank in their 2015 Chevy Silverado HD 2500 Crew Cab, which is a gasoline-powered vehicle. Similarly, another user with a 2015 GMC Sierra 2500HD mentions having the Titan 52-gallon tank in their truck without specifying any issues related to fuel type.
It is important to note that while the Titan 52-gallon tank may be compatible with both diesel and gasoline engines, users should always consult with experts or refer to reliable sources to ensure compatibility and adhere to safety regulations. Additionally, some users have reported issues with fuel gauges and spillage, so these factors should also be carefully considered before making any modifications.
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Some owners opt for a 45-gallon Transfer Flow tank, which fits standard bed LBZ
Owners of the Chevy Silverado 2500HD often seek to replace their 26-gallon fuel tanks with larger alternatives. While some opt for custom-made solutions, others choose the Titan 50-gallon or 52-gallon diesel tank as a replacement.
For those seeking an even larger capacity, the Transfer Flow 40-gallon in-bed auxiliary fuel tank system is an option that fits under the tonneau cover. This tank features a hard-wired controller with a suction cup for the windshield, and an optional bed liner coating.
However, if you're specifically seeking a 45-gallon tank, the Transfer Flow option is a popular choice. This tank is designed to fit the 2006-2007 6.6L LBZ Duramax engine, sitting above the differential without the need for a skid plate. It is constructed from 12-gauge ReliaSteel, a high-yield US aluminized steel, providing superior durability and strength. The tank mounts inside the frame rail and includes internal baffles to reduce fuel sloshing.
The 45-gallon Transfer Flow tank is a great solution for those seeking to maximise their fuel capacity and driving range without sacrificing truck bed space. It provides the convenience of filling up when prices are favourable and eliminates frequent fuelling stops.
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GM offers a second fuel tank behind the axle on 3500 chassis cab models, which may also fit the 2500
If you're looking to increase the fuel capacity of your 2500HD, there are a few options to consider. Firstly, GM does offer a second fuel tank for the 3500 chassis cab models, which can also fit the 2500HD. This tank is installed behind the axle and takes up the space typically occupied by the spare tire. It's a cost-effective option, with OEM-style rear fuel tanks being significantly cheaper than aftermarket alternatives.
The capacity of these rear fuel tanks varies, with some holding 22 to 31 gallons, while others can hold up to 30 gallons. It's important to note that installing this tank may require dealing with plumbing and figuring out the hookup, as well as losing the spare tire.
Additionally, there are other options for larger fuel tanks that are available for the 2500HD. For example, some owners have opted for a 45-gallon Transfer Flow frame-mounted gas tank, which offers increased fuel capacity but may require careful consideration of filling locations to avoid overpaying for gas.
Another option is to explore aftermarket solutions, such as the Titan Fuel Tanks. These tanks can provide a significant increase in fuel capacity, with some replacing a 26-gallon tank with a 52-gallon tank. However, it's important to note that some of these aftermarket options may be diesel-specific, so it's essential to carefully review the product specifications before making a purchase.
Ultimately, the decision to install a larger fuel tank depends on your specific needs and budget. While larger fuel tanks can provide increased range and reduce the frequency of fuel stops, they may also come with installation challenges and potential trade-offs, such as losing the spare tire. It's always recommended to consult with a qualified mechanic or a specialist in fuel tank installations to ensure the best outcome for your vehicle.
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One owner replaced their 39-gallon tank with a 67-gallon Titan tank for a trip to Alaska, reducing fuel stress
One owner of a 2001 Ford F350 replaced their 39-gallon tank with a 67-gallon Titan tank for a trip to Alaska, reducing fuel stress. They had heard that diesel availability in British Columbia and the Yukon region of Canada might be a challenge, so they opted for a larger tank. This gave them the flexibility to be choosy about where they purchased diesel and greatly extended their driving distance, reducing the stress of needing diesel as often.
The owner mentioned that the larger tank allowed them to shop for lower fuel prices without having to fill up every time they passed a fuel station. This is a common benefit cited by owners who have installed larger fuel tanks. For example, the owner of a 2008 Chevy 2500HD installed a 45-gallon Transfer Flow frame-mounted gas tank, which allowed him to fill up where gas was cheap. Similarly, the owner of a 2014 Sierra 1500 spoke about how they had not been able to find a replacement or auxiliary tank for their truck but wanted to extend their range for trips. They installed a Titan 67-gallon fuel tank, which allowed them to make trips to Southern California without refueling, saving money as diesel was cheaper in Arizona.
The Titan fuel tanks are made of corrosion-proof, high-density cross-linked polyethylene (XLHDPE) and are backed by a 5-year or 50,000-mile limited warranty. They are known for their toughness and durability. The installation process for the Titan tanks is generally straightforward and can be completed within a few hours.
It is worth noting that some owners have mentioned challenges with credit card fill-ups when they have larger tanks, as the pump sometimes shuts off before the tank is full due to station dollar limits. However, overall, the increased fuel capacity provided by the larger tanks can offer significant advantages, especially for those embarking on long-distance trips or facing limited fuel availability in certain regions.
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Frequently asked questions
Yes, it is possible to replace the fuel tank on a 2500HD. Owners of 2500HDs have replaced their stock 26-gallon fuel tanks with 45-gallon Transfer Flow tanks, 52-gallon Titan tanks, and 67-gallon Titan tanks.
A larger fuel tank means fewer fuel stops, and the ability to fill up when prices are cheaper.
One user reported that the drawback of a larger fuel tank is the possibility of filling up the tank and then seeing a cheaper gas price elsewhere.
