Replacement Fuel Tanks: Where To Source Them

If you're experiencing issues with your vehicle's fuel tank, it may be time to replace it. Fuel tanks can be damaged by accidents or simply by the wear and tear of daily driving, and it's important to get a replacement as soon as possible if your tank is leaking. When choosing a replacement fuel tank, you may opt for either steel or plastic polyethylene tanks, each with their own advantages and disadvantages. Steel tanks are often more cost-effective, while polyethylene tanks are lighter, more fuel-efficient, and corrosion-resistant. You can purchase replacement fuel tanks from various retailers, including Amazon, Raybuck, Gas Tank Depot, and Transfer Flow, with prices ranging from under $100 to over $300.

Online retailers

There are several online retailers that offer replacement fuel tanks. Here is a list of some popular options:

Amazon

Amazon offers a wide range of automotive replacement fuel tanks, with over 3,000 results available on their website. They provide free shipping on eligible orders and have a variety of brands, such as Dorman, Spectra Premium, and DNA MOTORING. Amazon also offers fast delivery options and allows customers to compare prices and read reviews before purchasing.

Transfer Flow

Transfer Flow specialises in aftermarket fuel tank systems, offering high-capacity replacement fuel tank systems made from aluminised steel for superior durability. Their products are designed to meet the needs of demanding drivers, providing an extended driving range and reducing the need for frequent fuel stops. Transfer Flow's replacement fuel tanks come with all the necessary parts for installation and are backed by a 6-year, unlimited-mile warranty.

S&B

S&B offers high-capacity replacement fuel tanks specifically designed for diesel applications. Their tanks include all the necessary components for installation and feature extreme corrosion resistance. S&B also provides a free service to recalibrate the distance-to-empty (DTE) in select vehicles to reflect the larger tank capacity. Their products are backed by a limited lifetime warranty and are made from high-quality high-density crosslink polyethylene.

Gas Tank Depot

Gas Tank Depot provides replacement fuel tanks that are designed for a correct fit and easy installation. They offer corrosion-resistant steel tanks and high-density, cross-linking polyethylene fuel tanks. Their products are built to handle the wear and tear that vehicles are exposed to daily, ensuring reliable performance. Gas Tank Depot carries replacement fuel tanks for various vehicle brands, including Austin-Healey, Chevrolet, Mercedes Benz, and Volkswagen.

Local auto shops

When visiting a local auto shop, you can expect to find replacement fuel tanks from well-known brands such as Ford, GM, Toyota, and Jeep. The staff at these shops are often knowledgeable about the products they sell and can guide you in choosing the right fuel tank for your vehicle. They may also provide additional accessories and hardware needed for a successful fuel tank installation.

In addition to purchasing a replacement fuel tank, local auto shops can be a valuable resource for other car-related inquiries. These shops often cater to automotive enthusiasts who enjoy working on their vehicles and may offer advice or recommendations for your specific needs. You can also inquire about other replacement parts, such as straps and fuel tank sending units, to ensure that you have everything necessary for a smooth installation process.

When visiting your local auto shop, be sure to know the specifics of your vehicle, including the make, model, and year. This information will help the staff guide you toward the most compatible and suitable replacement fuel tank options. Additionally, be mindful of any unique requirements or modifications your vehicle may have, as this can impact the type of fuel tank you need.

Dealerships

When visiting a dealership, you can expect to find replacement fuel tanks made from various materials, including steel and polyethylene. Dealerships typically carry replacement fuel tanks for a variety of car models, including popular brands such as Ford, Chevrolet, Toyota, and Jeep. Some dealerships also offer accessories and hardware related to fuel tanks, such as straps and fuel tank sending units.

One advantage of purchasing from a dealership is the assurance of quality. Dealerships often provide fuel tanks that are designed for a correct fit and easy installation. They may also offer warranties or guarantees, ensuring peace of mind with your purchase. Additionally, dealerships can provide guidance on fuel tank maintenance and help you address any issues that may arise.

When visiting a dealership, it is essential to have the necessary information about your vehicle, including the make, model, year, and fuel tank capacity. This information will help the dealership staff guide you toward the most suitable replacement fuel tank for your car.

Overall, dealerships are a reliable source for purchasing replacement fuel tanks. They offer a wide range of options, provide expert advice, and ensure a hassle-free purchasing experience.

Fuel tank materials

Fuel tanks are typically made of metal or plastic. Metal tanks are usually made of steel or aluminium, while plastic tanks are usually made of high-density polyethylene (HDPE).

Metal Fuel Tanks

Metal fuel tanks are typically made by welding stamped sheet metal parts together. Steel tanks are cost-effective and recyclable, but they are heavy and susceptible to corrosion. Aluminium tanks are lightweight, strong, and corrosion-resistant, but they are more expensive and susceptible to galvanic corrosion if they come into contact with certain metals, such as copper alloys.

Plastic Fuel Tanks

Plastic fuel tanks are typically made using blow moulding, which allows for more complex shapes. HDPE plastic is suitable for short-term storage of diesel and gasoline, but it has the potential to become saturated over time as fuels permeate the material. Cross-linked polyethylene (XPE) is another type of plastic used for fuel tanks, offering corrosion resistance and leak-proof properties due to its seamless construction. However, XPE tanks lack the flexibility to accommodate inspection or clean-out ports and cannot be cut or drilled for additional fittings.

Installation

Installing a replacement fuel tank can be a time-consuming and messy job, so it is recommended for experienced automotive DIY enthusiasts. The first steps are to remove the fuel pump relay and disconnect the negative battery cable. Drain as much fuel as possible from the old fuel tank. Then, disconnect the fuel filler hose and the fuel pump wiring harness. Be sure to support the fuel tank with a block of wood and a jack, and then loosen and remove any bolts from the straps holding the fuel tank in place.

Next, disconnect the fuel lines from the fuel pump. If needed, carefully hammer the retaining ring with a screwdriver or another sturdy tool to gain access to the fuel pump. Insert the fuel pump into the new tank and tighten the retaining ring. Having an assistant will help to get the new fuel tank into place. Slowly jack it up while an assistant holds it, then re-tighten the straps to keep it in place.

Finally, reconnect the fuel lines and the fuel filler hose. Tighten any hose clamps. Then, reconnect the fuel pump relay and the negative battery cable.

Most replacement fuel tanks come with all the parts needed for installation, including straps and mounting hardware. However, it is important to check this before purchasing.

It is also important to note that the exact location of a vehicle's fuel tank depends on the make and model, but they are commonly located before or after the rear axle, and strapped to the undercarriage of the automobile. Most cars and light trucks only have a single tank, but some larger trucks and vans have two.

Frequently asked questions