Katerina Swanson
Auxiliary fuel tanks, also known as transfer or add-in tanks, are extra fuel tanks that work in conjunction with a stock OE fuel tank. They are often installed to increase driving range and provide peace of mind during extended trips or remote area exploration. While some auxiliary tanks are mounted beneath a vehicle, they can also be installed on top of the stock tank in a truck bed. The installation process typically involves marking and drilling holes, bolting the tank in place, and connecting the fuel transfer mechanism to the truck's existing system.
How to install an extra fuel tank on a truck
| Characteristics | Values |
|---|---|
| Type of fuel tank | Auxiliary/transfer/"add-in" tank |
| Installation process | Requires lifting the truck, marking the placement of the tank, drilling holes, and bolting the tank into place |
| Mounting options | Beneath the vehicle or on top of the truck bed |
| Customization | Custom-crafted to match the specific make and model of the truck |
| Fuel transfer mechanism | Connected to the truck's existing fuel system with a pump and hoses; some models allow for "fill on the go" with the press of a button |
| Safety considerations | Use appropriately sized jack stands when lifting the vehicle, do not get under the vehicle when it is only supported by the jack |
| Additional considerations | Use a brightly colored marking tool to mark drill holes, use a center punch to prevent drill bit from straying |
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What You'll Learn
Planning the installation
The next step is to decide on the method for running the fuel supply line from the auxiliary tank to the existing factory fuel tank. This may involve drilling an additional hole in the truck bed or accessing the underside of the truck bed through rubber plugs near the stake pocket support posts. It is crucial to have a clear plan for routing the fuel supply line to ensure a smooth installation process.
Before beginning the installation, it is advisable to have an extra set of hands to help lift the auxiliary fuel tank into place. This not only lightens the load but also helps prevent any scrapes or scratches to the truck's finish. Additionally, ensuring the truck is safely supported with appropriately sized jack stands placed on flat portions of the frame is vital if you need to lift the truck during the installation process.
Depending on the specific make and model of your truck, you may need to consider custom-crafted auxiliary fuel tanks that match your vehicle. This ensures a seamless installation without significant modifications. Referring to the instructions provided with the auxiliary fuel tank is also recommended, as they often include detailed guidance and may specify the necessary fittings and mounting hardware required for a successful installation.
Finally, safety considerations are paramount when planning the installation. This includes never getting under the vehicle when it is only supported by a jack. Additionally, some auxiliary fuel tank installations may require additional safety measures, such as enclosing the fuel cell, implementing bladder and foam systems, or installing a rubber mat between the battery pack and the auxiliary tank to minimise fumes.
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Lifting and placing the tank
First, ensure you have an extra set of hands to help with lifting the tank. While auxiliary diesel fuel tanks are typically not very heavy, having assistance can make the process smoother and prevent any damage to your truck's finish.
Next, determine the placement of the tank. Place the auxiliary tank in the bed of your truck, ensuring it is positioned away from the sides, front, and back of the bed. It is important to leave some space on all four sides of the tank to prevent it from rubbing against the truck bed, which could potentially damage the tank.
Once you have determined the ideal location, mark the holes where you will install the tank. Use a brightly coloured marking tool, such as a wax pen or chalk, to clearly indicate the mounting locations. This will ensure you don't mistakenly drill in the wrong place.
After marking the holes, remove the auxiliary tank from the truck bed. This is when you would use a centre punch on the marked locations to prevent the drill bit from straying. Start by drilling small pilot holes, then use a larger bit that matches the bolts you plan to use. Before drilling, always check the undercarriage of the truck bed to avoid drilling into your existing fuel tank or any other important components.
Now you are ready to place the auxiliary fuel tank back into position. Determine how you will run the rubber fuel supply line from the new tank to your existing factory fuel tank. Most owners drill another hole in the truck bed and thread the line down. Alternatively, you may be able to access the bottom side of the truck bed by removing rubber plugs near the stake pocket support posts in the corners. In this case, you would remove the rubber plug, cut a hole in its centre, insert the rubber fuel line, and then replace the plug before running the line down.
Finally, use bolts, nuts, and washers to fasten the auxiliary fuel tank securely in place. Having an extra pair of hands at this stage can be helpful to hold the nuts or bolts in place as you tighten them from the bottom or top of the auxiliary truck bed fuel tank.
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Marking the holes
First, place the auxiliary diesel fuel tank in the location where it will be installed. It is important to make sure that the tank is installed away from the sides, front, or back of the bed. This will ensure that there is some space on all four sides of the auxiliary fuel tank, preventing it from rubbing against the truck bed and causing potential damage.
Once the tank is properly located, you can begin marking the holes. Use a brightly coloured marking tool such as a wax pen or chalk to visibly mark the holes where you will attach the fuel tank. This will help you avoid drilling the wrong hole. Mark the mounting locations for the bolts that will secure the fuel tank in place.
After marking the holes, remove the auxiliary diesel fuel tank from the pickup bed. This will allow you to more easily punch the locations of the holes. It is recommended to use a centre punch on the marked locations to prevent the drill bit from straying from the desired location.
Now you are ready to drill the holes. Start by drilling a small pilot hole with a smaller drill bit. Then, use a drill bit that matches the size of the bolts you have chosen to drill the final hole. Before drilling, check the undercarriage of the truck bed to ensure there are no other components that may be damaged by drilling.
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Drilling the holes
First, you need to determine the placement of your auxiliary fuel tank. Place the tank in the desired location, ensuring that it is away from the sides, front, and back of the bed. This spacing is important to prevent the tank from rubbing against the truck bed and causing potential damage. Once you have found the perfect spot, mark the holes where you will install the tank. It is recommended to use a brightly coloured marking tool like a wax pen or chalk to clearly indicate the mounting locations.
After marking the holes, remove the auxiliary fuel tank from the pickup bed. This is an important safety precaution to avoid any accidental damage to the tank while drilling. Now, you can prepare to drill the holes. Start by centre punching the marked locations. This helps to guide the drill bit and prevent it from straying from the desired spot. Begin drilling with a small bit to create a "pilot hole". Then, switch to a larger bit that matches the size of the bolts you plan to use.
Before you start drilling, inspect the undercarriage of the truck bed thoroughly. Ensure there are no other components underneath the hole locations that could be accidentally damaged. This is a crucial step to avoid drilling into your existing fuel tank or any other essential parts. Once you have confirmed it is safe to drill, proceed with caution and create the final holes.
In some trucks, you may have the option to access the bottom side of the truck bed by removing rubber plugs near the stake pocket support posts. If this is possible in your truck, you can remove the plug, punch or cut a hole in the centre, insert the rubber fuel line, and then secure the plug back in place. This provides an alternative method for running the fuel supply line without drilling additional holes.
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Connecting the fuel supply line
When connecting the fuel supply line, you must first determine how and where you will run the line from the tank to your existing factory fuel tank. Most people choose to drill another hole in the truck bed and thread the line down to the factory tank filler neck. You can also gain access to the bottom side of the truck bed by removing the rubber plugs near the bottom of the stake pocket support posts in the corners of the truck bed. Once you've removed the rubber plug, punch or cut a hole in the centre to insert the rubber fuel line.
After deciding on the placement of the fuel supply line, you can then place your auxiliary fuel tank. Use the bolts, nuts, and washers to fasten the fuel tank in position. Before bolting the tank into place, it is recommended to visibly mark the holes where you will attach the tank to the bed of the truck. Use a brightly coloured marking tool, such as a wax pen or chalk, to avoid drilling mistakes. Once the markings are complete, remove the tank from the truck bed and drill the holes. Start with a small pilot hole and work your way up to a larger bit that matches the size of your bolts.
If you are installing a bottom sump with your pump, you may end up with an open fuel supply or return line. In this case, you will need to cap off these lines to prevent fuel from seeping out and dirt from entering your fuel tank. You can use a fuel line quick-connect plug to easily cap off these lines. Simply clip the quick-connect plug into the open factory fuel line.
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