Best Replacement Fuel Tanks For Ford Mustangs: Top Brands

A fuel tank is one of the most critical components of an automobile, and the Ford Mustang is no exception. Fuel contamination caused by in-tank corrosion can bring your Mustang to a standstill. While water in the fuel is the primary cause of corrosion, it is not the only one. Sediment and rust particles can also enter the fuel system, causing critical systems to wear out and reducing fuel efficiency. Therefore, it is essential to replace a rusty or damaged fuel tank with a new one. Several companies offer replacement fuel tanks for the Ford Mustang, including AutoZone, CJ Classics, TruGrade, Dorman, Replacement, Spectra Premium, and Sherman. These replacement fuel tanks are designed to fit specific Mustang models and years, ensuring a proper fit without any modifications. When replacing a fuel tank, it is also recommended to replace other fuel tank components such as the fuel sending unit, gasket, and hose.

Fuel tank size and weight

The original fuel tank in a Ford Mustang typically holds around 16 gallons of fuel. However, some replacement tanks offer larger capacities, such as 20 or 22 gallons, which can provide increased range. For example, CJ Classics offers a 20-gallon fuel tank for the 1971-1973 Mustang and a 22-gallon fuel tank for the 1970 model.

When considering a larger fuel tank, it is important to keep in mind that the extra fuel will add weight to the vehicle. This additional weight may impact the performance and handling of the car, particularly in older models. As one Mustang owner noted, the "downside" of a larger tank is the extra weight and the slightly higher position of the tank, which could reduce trunk space and prevent a full-size spare tire from fitting.

Another factor to consider is the material of the fuel tank, as this can impact both weight and durability. Stainless steel fuel tanks offer superior resistance to rust and corrosion compared to mild steel or galvanized tanks. However, they are also more expensive. One Mustang owner suggested that the extra money could be better invested in "a better suspension and superb tires."

Ultimately, the decision on fuel tank size and material depends on individual preferences and driving needs. If you prioritize range and corrosion resistance, a larger stainless steel tank could be a good option. On the other hand, if weight and cost are more important factors, a standard-sized mild steel or galvanized tank may be a more suitable choice.

Fuel tank material

Fuel tanks are typically made of metal or plastic. Metal tanks are usually built by welding stamped sheet metal parts together, while plastic tanks are usually made using blow moulding, which allows for more complex shapes.

Metal Fuel Tanks

Metal fuel tanks are typically made of steel or aluminium. Steel tanks are more susceptible to rusting than aluminium tanks, but are also less expensive.

Aluminium is light, strong, easy to cut and weld, non-sparking, and corrosion-resistant. However, it is susceptible to galvanic corrosion, which occurs when incompatible metals are attached in a wet or damp environment.

Steel tanks, on the other hand, are stronger and can be built to fit available accommodations. They are also relatively inexpensive, so using more material to account for sacrificial rusting is not an issue.

Plastic Fuel Tanks

High-density polyethylene (HDPE) is a common material for plastic fuel tanks. It is functionally viable in the short term, but in the long term, fuels like diesel and gasoline can permeate the HDPE material.

Plastic tanks are formed by blowing a thick continuous tube of HDPE within a mould that determines the final shape of the part. This process allows for complex shapes that can fit into the available space in a vehicle.

Stainless Steel Fuel Tanks

Stainless steel fuel tanks have also been tested and, while they are effective for flexible fuels, they are difficult to form without severe breakage during stamping. They are also expensive, with an estimated cost ratio to terne steel of 5:1.

Fuel tank kits

When choosing a fuel tank kit, you should consider the specific year and model of your Mustang, as well as whether it has electronic fuel injection. Kits typically include a replacement fuel sending unit, gasket, and hose, and some may also include a filler neck.

CJ Pony Parts Fuel Tank Kits:

CJ Pony Parts offers a range of fuel tank kits compatible with various Mustang models. Their kits include OEM-style replacements that are durable and easy to install. Some of their options include:

• Holley Sniper EFI Fuel Tank Kit with a 16-gallon or 22-gallon capacity, suitable for 1965-1970 Mustangs.
• Aeromotive Stealth Fuel Tank Kit Gen II with 340 or 200 LPH, suitable for 1965-1973 Mustangs.
• Fuel Tank Conversion Kit with a 22-gallon capacity, available in stainless steel, suitable for 1967-1968 Mustangs.
• CJ Classics Fuel Tank Premium with a drain plug, available for 1965-1967, 1970, and 1969 Mustang models.

AutoZone Fuel Tanks:

AutoZone offers a range of fuel tanks for Ford Mustangs, with a focus on providing an exact fit for your vehicle. While they do not explicitly mention fuel tank kits, they do offer a range of related parts that may be included or purchased separately, such as the fuel tank sending unit, fuel pump, fuel cap, and fuel filter.

Vintage Mustang Forums:

For vintage Mustang enthusiasts, the Vintage Mustang Forums provide a wealth of information and recommendations. While not a direct retailer, forum users offer insights and suggestions for fuel tank replacements, including:

• A 16-gallon stainless steel fuel tank with a drain plug, suitable for 1964-1968 Mustangs.
• NPD's 204358 fuel tank conversion kit, which includes everything needed for installation.
• CJPP's fuel tank kit, which includes a 22-gallon stainless steel tank and other necessary components.

Tanks, Inc.:

Tanks, Inc. offers a Universal Fuel Tank that can be used as a replacement for 1964-1968 Mustangs. It features a bolt-on neck with a billet cap or a 6" 2-1/4" ID rubber connector hose. The tank is available in EFI and carbureted versions, with internal baffling and a large fuel tray to prevent fuel pump starvation.

Late Model Restoration:

Late Model Restoration provides a one-stop-shop for Mustang fuel tanks and components. They offer factory-direct replacement tanks for 1979-1993 and 1994-2004 Mustangs, with options for carbureted or EFI models. They also carry a range of fuel tank components, such as gas tank shields, tank rubber seals, fuel filler neck grommets, and fuel tank straps. Additionally, they offer a 1987-1993 Gas Tank Kit for a fox body fuel tank swap.

Fuel tank maintenance

Maintaining your Ford Mustang's fuel tank is crucial to ensure optimal performance and longevity. Here are some detailed instructions and tips for fuel tank maintenance:

• Prevent Contamination: Fuel tanks can accumulate dirt, rust, and other contaminants over time. These impurities can mix with your fuel, leading to engine problems and reduced performance. Regularly check for leaks and get them repaired promptly to prevent contamination.
• Extend Equipment Life: Proper maintenance and regular cleaning help preserve the integrity of the fuel tank and related components, ultimately extending the life of your Mustang.
• Ensure Efficiency: A clean fuel tank ensures smooth fuel flow, preventing blockages and maintaining optimal engine performance.
• Avoid Costly Repairs: Regularly inspect your fuel tank and address any issues promptly. Neglecting maintenance can lead to severe damage, resulting in expensive repairs or replacements.
• Inspect for Contamination: Check your fuel tank for signs of rust, sludge, or water accumulation. Use a flashlight and mirror to get a clear view of the inside of the tank. If you notice any contaminants, have the tank professionally cleaned to avoid engine problems.
• Maintain Fuel Quality: Always use high-quality fuel from reputable fuel stations to minimize the risk of impurities. Fuel additives can also help maintain fuel quality, but they should not replace proper cleaning and maintenance.
• Replace Fuel Filters: The fuel filter traps impurities before they reach the engine. However, a dirty fuel tank can overwhelm the filter. Regularly replace clogged filters and consider using mesh filters (strainers) to prevent debris and sludge from entering the tank.
• Address Performance Issues: If you experience engine performance issues such as difficulty starting, misfires, rough idling, decreased power, or increased fuel consumption, it could be due to a contaminated fuel tank. Have your tank inspected and cleaned if necessary.
• Choose the Right Fuel Tank: When replacing your fuel tank, opt for a direct-fit replacement that is specifically designed for your Mustang's year and model. Consider fuel tanks with corrosion-resistant finishes to prevent rust and leaks.
• Consider Fuel Tank Kits: Fuel tank kits include a replacement fuel sending unit, gasket, and hose. They can be more cost-effective and convenient than purchasing individual components separately.
• Regular Fuel Level Checks: Maintain appropriate fuel levels in your tank. Running on a near-dry tank can lead to sediment formation, blockages, and potential damage to pumps and equipment.
• Clean Filler Caps and Gaskets: Remove filler caps periodically and clean the threads using a wire brush. Apply a small amount of lithium grease to prevent rust build-up. Also, inspect the gasket at the bottom of the cap to ensure it provides a good seal.
• Lubricate Hinges and Locks: Lubricate the hinges and locks of the cabinet cover or door to avoid rust and wear. Use PTFE grease on the moving parts of the locking mechanism. Replace any components that show signs of deterioration.
• Inspect Pumps and Filters: Regularly check pumps, vents, and valves to ensure proper fuel flow. Remove any debris or sludge that may accumulate in these areas. Inspect pumping equipment at least weekly to prevent blockages.
• Visual Inspection of the Tank: Keep the area around your tank clear of debris and vegetation to easily identify any leaks, drips, or spills. Visually inspect the tank for leaks every six to twelve months, depending on the nature of your operations.
• Remove Water and Debris: Remove any accumulation of water, diesel, or other products from the tank and its surrounding areas. Treat and dispose of any waste as hazardous material, following local regulations.
• Check Fuel Quality: Poor-quality fuel can damage your tank and equipment. Signs of poor fuel include a change in color, an unpleasant odor, equipment running differently (e.g., spluttering), and the build-up of sediment or sludge in the tank, filters, or pumps.

Fuel tank safety

Placement and Installation

It is crucial to install fuel storage tanks in suitable locations away from potential hazards, such as ignition sources, high-traffic areas, and buildings. Adhering to local regulations and guidelines during the installation process is essential, including obtaining the necessary permits and certifications. Regular inspections of the tank and its foundation should be conducted to identify any signs of damage or deterioration, with prompt remedial action taken.

Training and Safe Handling Procedures

Thorough training for employees handling fuel or involved in tank maintenance and inspections is imperative. They should understand the risks associated with fuel storage tanks, including fire hazards, fuel spillage, and the proper use of safety equipment. Emphasize the significance of adhering to safety protocols, such as wearing personal protective equipment (PPE) and utilizing appropriate tools when working with the tank.

Fuel Transfer Safety Measures

Specialized containers and equipment designed for fuel transfer help minimize the risk of spills and accidents. All fuel transfer connections and valves should be well-maintained, secured, and regularly inspected to prevent leaks or malfunctions.

Fire Safety Precautions

Install fire safety equipment, such as fire extinguishers, fire alarms, and smoke detectors, near the fuel storage tank, and ensure they are regularly maintained. Develop and communicate an emergency response plan that outlines the procedures to follow in the event of a fire or fuel-related incident. Ensure employees are trained in using firefighting equipment and have easy access to emergency contact information.

Fuel Spill Containment and Cleanup

Implement spill containment systems to prevent fuel spills during storage and transfers. Have spill response kits readily available to address any fuel spills promptly. Train employees on proper spill response procedures and the correct disposal of spilled fuel and contaminated materials.

Regular Inspections and Maintenance

Conduct regular inspections of the fuel storage tank for corrosion, leaks, or structural damage. Schedule routine maintenance to ensure that all components, including valves, pumps, and gauges, are functioning correctly. Maintain detailed records of inspections, maintenance, and repairs for reference and compliance purposes.

Fuel Tank Design and Construction

Fuel tanks, whether for aircraft or vehicles, should be designed and constructed to withstand various stresses and forces. Aircraft fuel tanks, for example, are made from resilient materials like aluminium alloys or composite materials to resist corrosion and leakage.

Fuel System Components

It is essential to properly maintain and inspect fuel system components such as fuel lines, pumps, valves, and filters to ensure they are free from defects or damage that could lead to fuel leaks or malfunctions.

Fuel Tank Inerting

Fuel tank inerting is a process that replaces the potentially flammable gas space above the fuel (known as ullage) with a non-flammable atmosphere, reducing the risk of fire or explosion. This technique is commonly used in military applications.

Fuel Tank Ventilation

Proper airflow and ventilation systems are crucial to preventing vapour buildup and pressure spikes in fuel tanks, which could lead to explosions. These systems are meticulously designed and maintained to ensure a constant flow of fresh air and pressure relief.

Fuel Tank Sealing

Sealing fuel tanks is essential to prevent fuel leaks and spills. Any cracks, holes, or signs of damage to the fuel tank must be promptly addressed and repaired to maintain the integrity of the fuel system.

Frequently asked questions