Mercedes Mullins
Ford Transit owners and enthusiasts have been discussing the possibility of adding an auxiliary fuel tank to extend the range of their vehicles. The general consensus is that it is not a simple process and there are legal and safety considerations to take into account. For example, one user highlights that per DOT rules, it is not permissible to simply plumb in a gravity feed into the main tank. Another user suggests using two fuel pumps with check valves between the main tank and a stealth aux tank, but warns of potential issues with evaporative emissions. While some companies like Transfer Flow offer auxiliary tank systems, they can be expensive, with a 75-gallon tank costing around $1,100. Installation of an auxiliary fuel tank requires adhering to regulations such as ensuring fuel lines are not near flame or heat sources and are contained within the body of the vehicle.
| Characteristics | Values |
|---|---|
| Fuel tank capacity | 300-330 miles per tank |
| Average range | 350-400 miles |
| Suggested replacement tank capacity | 40 gallons |
| Average fuel efficiency | 15 MPG |
| Suggested replacement tank range | 600 miles |
| Fuel port location | Under the van, halfway along the fuel tank |
| Fuel port connection | Blue item retained by a red plastic removal interlock |
| Fuel port connection adapter | 5/16" male Bundy Tube adapter |
| Fuel port connection adapter fitting | 3/16" barb fitting |
| Fuel line tool | Fuel line disconnect tool |
| Fuel tank system | Transfer Flow's Trax-II |
| Fuel tank capacity (refuel tank) | 82 gallons |
| Fuel tank capacity (auxiliary tank) | 75 gallons |
| Fuel tank cost (refuel tank) | $654 |
| Fuel tank cost (auxiliary tank) | $1,100 |
| Fuel tank website | www.titanfueltanks.com |
| Fuel tank system regulations | 49CFR393.65, Fuel Systems |
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What You'll Learn
The cost of adding an auxiliary fuel tank
It is worth noting that some auxiliary fuel tanks can hold up to 100 gallons of additional fuel, providing significant convenience and peace of mind while on the road. However, the cost of filling up larger tanks can be substantial, with fill-ups costing up to $180 or even $250 in Canada.
Additionally, there may be considerations regarding local laws and regulations for auxiliary fuel tanks, particularly for gravity-fed systems. The installation process may also vary, with some tanks requiring simple bolt-on solutions, while others may need more complex modifications.
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Connecting the tank to the aux fuel port
Connecting an auxiliary fuel tank to your Ford Transit can be a complex process, and there are a number of regulations that need to be followed to ensure safety and legality.
Firstly, it is important to source the correct parts. One user recommends a 5/16" male Bundy Tube adapter that transitions into a 3/16" barb fitting, allowing a connection to the fuel pump of a hydronic system. This user also notes that removing the blue cap/plug from the aux fuel port was challenging and required a fuel line disconnect tool.
Another user has a different experience, opting for a Webasto Ford Transit aux fuel sender kit. This kit included a diagram with a specific cut line for the aux fuel port nipple, which, when correctly cut, allowed for a secure connection.
When connecting the tank, it is important to follow safety regulations, such as ensuring that fuel lines are not placed near flame or heat sources, like the exhaust system, and that they are not located outside the body of the vehicle or in the interior/passenger area.
One user suggests a creative solution of adding a fuel cell and running a transfer pump to the main tank, but it is unclear if this method would cause any issues with the evap system.
It is worth noting that there are companies that specialize in auxiliary fuel tank systems, such as Transfer Flow's Trax-II, which provides an integrated system with a working fuel gauge. However, these systems can be expensive, and it may be necessary to purchase the entire tank setup to access the required parts.
Overall, while adding an auxiliary fuel tank to a Ford Transit is possible, it is a complex task that requires careful planning and consideration of safety and legal regulations.
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The legality of adding an auxiliary fuel tank
The legality of installing an auxiliary fuel tank depends on several factors, including the vehicle type, the fuel type, the tank's capacity, and the jurisdiction.
In the United States, for example, there are federal regulations governing the installation of auxiliary fuel tanks. One key regulation states that gravity-fed auxiliary fuel tanks are illegal for gasoline-powered vehicles. This means that an auxiliary tank can have a hand or electric pump/transfer device, but it cannot be gravity-fed into the main tank. Interestingly, this regulation does not apply to diesel-powered vehicles, where auxiliary diesel tanks are exempt.
Additionally, there are safety requirements that must be met for any auxiliary fuel tank installation. For instance, fuel tanks must be clearly and permanently marked with specific information, including the manufacturer's name, manufacture date, gallon size, and compliance with FMCSA (Federal Motor Carrier Safety Administration) requirements. The fuel connections from the auxiliary tank to the primary system must not interfere with the normal functions of the primary system, and the auxiliary tank's lines, fittings, valves, and connections must be of an adequate size to ensure proper fuel flow. Furthermore, fuel withdrawal fittings must be located above the normal level of fuel in the tank when full, and larger tanks over 25 gallons must have a venting system to prevent rupture during a fire.
It is important to note that regulations can vary by state, as evidenced by California's unique restrictions on fuel can sizes. Therefore, it is essential to consult the specific laws and regulations applicable to your jurisdiction before installing an auxiliary fuel tank.
In terms of Ford Transit vehicles, there are online forums where users discuss the possibility of adding an auxiliary fuel tank. Some users have suggested companies that may be able to build custom fuel tanks, while others have proposed workarounds such as using additional fuel pumps or carrying extra fuel cans. However, it is unclear whether these modifications are legal, and official sources should be consulted for definitive answers.
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The size of the tank
The size of the auxiliary fuel tank you need for your Ford Transit van depends on your requirements. If you drive around 100 miles per day, a standard tank may not be sufficient, as it will require refuelling every three days. In this case, an auxiliary tank could be a good option to extend the range of your Transit.
One option is to install a 40-gallon tank, which would provide a range of approximately 600 miles, based on a 15 MPG average. This should be sufficient for most current Transits. However, it is important to consider the space available for the tank. The undercarriage of the van may not have sufficient room for a large tank, so it is essential to check before making any purchases.
Another option is to use a smaller auxiliary tank, such as a 20-gallon tank. This would allow you to pump additional fuel into the main tank when the low fuel light comes on. This option provides flexibility and can be a good choice if space is limited.
Additionally, there are larger tanks available, such as a 45-gallon replacement fuel tank, which can increase the fuel capacity and driving range of your van. This option may be worth considering if you require even more extended range.
It is also possible to find auxiliary tanks of various sizes, such as a 30-gallon spare tire tank, which may require modification to fit your Transit. When choosing an auxiliary fuel tank, it is important to consider the size, compatibility, and any necessary modifications to ensure a safe and functional installation.
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The location of the aux fuel port
The Ford aux fuel connection is typically identified by a red connector, which is designed to supply the hydronic fuel pump. To connect to the aux fuel port, an adapter is required, such as a 5/16" male Bundy Tube adapter, which can be transitioned into a suitable barb fitting. It is important to ensure that the correct size fuel lines and fittings are used for the specific system.
In some cases, the aux fuel port may be located on the side of the fuel tank, as mentioned in a user's experience with a Webasto Ford Transit aux fuel sender kit. This kit included a diagram specifying the cut line for the aux fuel port nipple, which is an important detail to ensure proper installation.
It is worth noting that there are regulations governing the installation of auxiliary fuel tanks and their associated fuel lines. These regulations, such as 49CFR393.65, Fuel Systems, outline important safety considerations. For example, fuel lines should not be placed near flame or heat sources, such as the exhaust system, and should be contained within the body of the vehicle, away from the interior or passenger areas.
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Frequently asked questions
There are several options for adding an auxiliary fuel tank to your Ford Transit. You can either purchase a tank from a company like Transfer Flow or Titan Fuel Tanks, or you can install a system of multiple tanks, such as the Hein double battery holder. If you want to connect to the aux fuel port, you will need to remove the blue cap/plug, which can be challenging.
There are several regulations outlined in 49CFR393.65, Fuel Systems that you need to comply with when installing an auxiliary fuel tank. These include not having any fuel lines near flame or heat sources, such as the exhaust system, and not having fuel lines outside the body of the vehicle or in the interior/passenger area.
You will need to purchase an auxiliary fuel sender kit, such as the Webasto Ford Transit kit or the Eberspacher kit. You will then need to cut the auxiliary straw that goes into the nipple according to the specified cut line, push the elbow connector on, hook it up, and remount the fuel tank.
An auxiliary fuel tank can extend the range of your vehicle, reducing the frequency of refuelling. This can be particularly useful if you travel long distances or in areas where gas stations are scarce.
