Aftermarket gas tanks for trucks solve range anxiety, replace rusted originals, or increase fuel capacity for towing and overlanding. We researched and compared manufacturer specifications, safety standards (including CARB and DOT compliance), and aggregated owner feedback to evaluate the top options. This guide covers replacement tanks, auxiliary tanks, and high-capacity units for popular truck models. Our evaluation focuses on fitment, material durability, ease of installation, and value for the upgrade.
| Photo | Product | Score | Buy |
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Transfer Flow 60 Gallon Replacement Fuel Tank Best Overall Replacement 60 gallons, aluminized steel, CARB/EPA compliant for select diesel trucks |
9.2 | 🛒 Check Price |
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RDS Manufacturing 50 Gallon Auxiliary Fuel Tank Best Auxiliary Tank 50 gallons, diamond plate aluminum, bed-mounted with tool box combo |
8.8 | 🛒 Check Price |
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Titan Fuel Tanks 53 Gallon Replacement Tank Best for Ford Super Duty 53 gallons, cross-linked polyethylene, direct fit for Ford F-250/F-350 diesel |
8.7 | 🛒 Check Price |
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Aero Tanks 60 Gallon Replacement Tank Best for GM Trucks 60 gallons, steel with powder coat, fits Chevy Silverado/GMC Sierra 2500/3500 diesel |
8.4 | 🛒 Check Price |
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S&B Filters 60 Gallon Replacement Tank Best for Ram Trucks 60 gallons, cross-linked polyethylene, fits Ram 2500/3500 diesel |
8.3 | 🛒 Check Price |
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LRA Auxiliary Fuel Tank 40 Gallon Best Compact Auxiliary 40 gallons, aluminum, bed-mounted with tie-down points |
7.8 | 🛒 Check Price |
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Fuel Exchange 30 Gallon Replacement Tank Budget Pick 30 gallons, steel with black paint, universal fit for older trucks |
7.2 | 🛒 Check Price |
1. Transfer Flow 60 Gallon Replacement Fuel Tank: Best Overall Replacement
Transfer Flow is a well-known name in aftermarket fuel tanks, and their 60-gallon replacement tank is a favorite among diesel truck owners. In our evaluation, we compared its aluminized steel construction against competitors and found it offers excellent corrosion resistance. Owner feedback highlights the straightforward installation for those with basic mechanical skills, though some noted the tank’s weight makes it a two-person job. The tank is CARB and EPA compliant, which is crucial for emission-regulated states.
However, this tank is primarily designed for diesel trucks; gasoline model owners should verify compatibility. The added weight when full can reduce payload, so it’s best for those who prioritize range over maximum cargo capacity. If you have a gas truck or need a lighter option, consider a plastic auxiliary tank instead.
- Direct replacement for factory tank on many Ford, Chevy, and Ram diesel models
- Aluminized steel construction with internal baffles for fuel stability
- Includes all necessary hardware and sending unit adapter
Pros: Significant range increase without losing bed space; High-quality construction with corrosion-resistant coating
Cons: Heavy when full, may reduce payload capacity; Not compatible with all gasoline trucks
2. RDS Manufacturing 50 Gallon Auxiliary Fuel Tank: Best Auxiliary Tank
RDS Manufacturing’s 50-gallon auxiliary tank is a smart solution for truck owners who need extra fuel without permanently modifying the vehicle. We researched its diamond plate aluminum construction and found it to be both durable and significantly lighter than steel tanks. Owner feedback consistently praises the integrated tool box, which keeps the bed organized. The included 12-volt transfer pump is convenient for refueling equipment or transferring fuel to the main tank.
The main drawback is that it occupies a portion of the truck bed, reducing space for other cargo. Also, some users report the pump can be slow, especially in cold weather. This tank is ideal for those who need occasional range extension and want the added utility of a tool box, but not for those who require full bed access.
- Rotomolded diamond plate aluminum for lightweight strength
- Integrates with a lockable tool box for dual functionality
- Includes 12-volt pump and auto-shutoff nozzle
Pros: Frees up bed space with combined storage; Aluminum is lighter than steel and resists rust
Cons: Takes up bed space, reducing cargo area; Pump may be slow for rapid refueling
3. Titan Fuel Tanks 53 Gallon Replacement Tank: Best for Ford Super Duty
Titan Fuel Tanks specializes in plastic replacement tanks, and their 53-gallon unit for Ford Super Duty trucks is a top contender. We compared its cross-linked polyethylene against steel alternatives and found it offers excellent resistance to corrosion and dents. Owner feedback highlights the simple bolt-in installation; many completed it in a few hours. The tank is designed to fit in the factory location, preserving ground clearance.
However, plastic can be vulnerable to punctures from sharp objects off-road, though Titan uses thick-wall construction. The 53-gallon capacity is generous but less than some steel 60-gallon tanks. This is a great pick for Super Duty owners in rust-prone areas who want a straightforward upgrade, but not for extreme off-road use where impact resistance is critical.
- Rotomolded polyethylene is lightweight and corrosion-proof
- Bolt-in installation with no cutting or drilling required
- Includes fuel sender and all mounting hardware
Pros: No rust concerns like steel tanks; Easy installation with clear instructions
Cons: Plastic may be less impact-resistant than steel; Slightly smaller capacity than some steel options
4. Aero Tanks 60 Gallon Replacement Tank: Best for GM Trucks
Aero Tanks offers a 60-gallon replacement for GM diesel trucks that we evaluated based on owner feedback and spec sheets. The powder-coated steel construction provides solid protection against rust, though some users in harsh climates reported minor corrosion over time. Installation is generally straightforward, but the tank’s weight can be challenging without a lift. The included sending unit is a nice touch, but a few owners noted it didn’t read accurately.
This tank is a good value for GM truck owners who want maximum capacity. However, if you prioritize weight savings or need precise fuel gauge readings, you might consider a polyethylene tank like the Titan. It’s best for those who don’t mind a bit of extra weight and can tolerate potential sending unit quirks.
- Powder-coated steel for durability and corrosion resistance
- Includes fuel level sending unit and filler neck
- Designed for easy installation with no modifications
Pros: Large capacity for long hauls; Good fitment reported by most owners
Cons: Some reports of sending unit accuracy issues; Heavier than plastic alternatives
5. S&B Filters 60 Gallon Replacement Tank: Best for Ram Trucks
S&B Filters is known for air intakes, but their 60-gallon replacement tank for Ram trucks is a solid option. We researched its cross-linked polyethylene construction and found it to be durable and rust-free. Owner feedback generally praises the fit and finish, though a few mentioned the strap alignment required patience. The tank includes all necessary components, making it a complete kit.
The main downside is the price, which is higher than comparable steel tanks. Additionally, the plastic material may not be as resistant to impacts as steel. This tank is best suited for Ram diesel owners who want a lightweight, corrosion-proof solution and are willing to invest in a premium product.
- Lightweight plastic with UV-stabilized additives
- Includes fuel sender, cap, and vent kit
- Easy bolt-in installation with no drilling
Pros: Corrosion-proof and lightweight; Good support from manufacturer
Cons: Higher price than some steel tanks; Some owners report difficulty aligning the tank straps
6. LRA Auxiliary Fuel Tank 40 Gallon: Best Compact Auxiliary
LRA offers a 40-gallon auxiliary tank that we evaluated as a compact option for trucks with limited bed space. The aluminum construction is lighter than steel and resists corrosion. Owner feedback notes that the low-profile design is less intrusive, but some found the installation instructions lacking. The included pump works well for transferring fuel.
However, the 40-gallon capacity is modest compared to other auxiliary tanks, and it still takes up bed space. This tank is best for those who need a moderate range boost without sacrificing too much cargo area. It’s not ideal for serious overlanders who need maximum fuel capacity.
- Aluminum construction with welded seams
- Low-profile design to preserve bed visibility
- Includes 12-volt pump and hose
Pros: Compact and relatively lightweight; Aluminum resists rust well
Cons: Smaller capacity may not suit long-haulers; Installation may require drilling into bed
7. Fuel Exchange 30 Gallon Replacement Tank: Budget Pick
Fuel Exchange’s 30-gallon tank is a budget-friendly option for those needing to replace a rusted or damaged tank. We researched its universal design and found it can fit many older trucks with some adjustments. Owner feedback is mixed; some appreciated the low cost, while others reported that the tank required extra work to fit properly. The steel construction is basic and may need a protective coating to prevent corrosion.
This tank is best for owners of older trucks who are on a tight budget and have some fabrication skills. It’s not recommended for newer trucks or those who want a simple drop-in replacement. If you value ease of installation and long-term durability, consider spending more on a model-specific tank.
- Universal design with adjustable mounting brackets
- Economical option for replacing rusted tanks
- Includes drain plug and fuel sender
Pros: Very affordable price point; Works on many truck models
Cons: Steel may rust quickly without additional coating; Fitment may require modifications
Frequently Asked Questions
Are aftermarket gas tanks legal for street use?
Many aftermarket gas tanks are CARB and EPA compliant, meaning they are legal for street use in all 50 states. However, some are only for off-road use. Always check the product specifications for compliance before purchasing.
How difficult is it to install a replacement gas tank?
Installation difficulty varies by vehicle and tank type. Most replacement tanks are designed as direct fit and can be installed with basic hand tools in a few hours. Auxiliary tanks often require drilling and wiring for the pump. If you are not comfortable working with fuel systems, professional installation is recommended.
Will a larger gas tank affect my truck's payload capacity?
Yes, a larger tank adds weight when full. For example, diesel weighs about 7 pounds per gallon, so a 60-gallon tank adds over 400 pounds when full. This reduces your available payload. Consider this if you frequently haul heavy loads.
Can I use an auxiliary tank to fuel other vehicles or equipment?
Yes, many auxiliary tanks come with a transfer pump and nozzle, allowing you to fuel other vehicles, ATVs, or equipment. This is a common use for farmers and off-road enthusiasts.
What is the difference between a replacement tank and an auxiliary tank?
A replacement tank takes the place of your factory tank, increasing capacity without losing bed space. An auxiliary tank is installed in the truck bed and works alongside the factory tank, often with a transfer pump. The choice depends on whether you prefer more range without sacrificing bed space or need additional fuel without modifying the factory system.
Our Verdict
After researching and comparing the top aftermarket gas tanks for trucks, our top pick is the Transfer Flow 60 Gallon Replacement Fuel Tank for its excellent build quality, CARB compliance, and direct fitment for many diesel trucks. The runner-up is the RDS Manufacturing 50 Gallon Auxiliary Fuel Tank, which offers a flexible combination of extra fuel and tool box storage, ideal for those who need occasional range extension.
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