The Essential Guide to Choosing the Right High-Capacity Fuel Tank Upgrade for Your Diesel Truck or Van

A larger, high-capacity fuel tank gives you:

• Hundreds more miles of range

• Fewer interruptions when towing or hauling

• Ability to fuel where prices are better

• More freedom in remote areas

• A larger safety buffer for winter travel, rural routes or long climbs
  

A 60-gallon high-capacity replacement fuel tank can push towing range into the 500–600 mile window depending on load, terrain and driving style.

A high-capacity replacement fuel tank installs in the OEM location and integrates cleanly with the truck’s factory systems. It’s the simplest, most reliable way to add real range without sacrificing bed space.

A well-engineered high-capacity replacement fuel tank reuses the factory sending unit, so your fuel gauge behaves as expected, no guessing, no secondary displays, no clutter.

Auxiliary in-bed or frame-mounted tanks move fuel into the main tank via gravity or a transfer pump. They can be functional, but they also introduce:

• Additional plumbing

• Higher risk of incorrect installation

• Potential overfill conditions

• Lost bed or cargo space
  

Replacement tanks avoid those issues entirely.

Gauge accuracy is preserved because the sending unit remains in its original alignment.

DTE behavior varies by platform:

• Many Ford Powerstroke and Sprinter Van platforms support Distance to Empty recalibration with a module that plugs into the vehicle's computer, which updates the system to reflect the new tank size.
  

• On GM Duramax and Dodge Ram Cummins trucks, DTE continues calculating based on the factory capacity, meaning the gauge remains accurate, but DTE may under-report.

High-capacity replacement tanks maintain critical safety features, including rollover protection and required vapor space. 

Overfilling, particularly through improperly installed auxiliary systems, can defeat these safety features, which is why replacement tanks are the preferred solution for simplifying range expansion.

Trying to figure out which high-capacity fuel tank replacement makes the most sense for your diesel truck? This reference chart lays out S&B’s key tank sizes by platform so you can quickly see how much range each option adds and how it fits into your daily driving routine.

Each S&B tank installs in the stock location and is engineered to maximize underbody space, extend your driving range and maintain accurate fuel readings, while preserving full use of your bed for trailers, gear and equipment.

Upgrading is straightforward, but choosing the right tank requires attention to a few key details.

This ensures the high-capacity replacement fuel tank you select fits your truck or van as intended. High-quality, reliable suppliers like S&B will typically have an in-house fitment expert you can talk to for guidance or a fitment search tool on their website to guide you on choosing the right fuel tank for your specific vehicle.

Look for thick, impact-resistant materials and a one-piece construction that eliminates rust, delamination, corrosion or condensation concerns. Tanks built from cross-linked polyethylene (XLPE) combine seamless one-piece construction, exceptional impact resistance, and built-in corrosion immunity, avoiding the rust or weld-seam leaks that plague metal tanks under road and weather stress.

A well-designed high-capacity replacement fuel tank keeps the factory fuel gauge accurate because it reuses the OEM sending unit. What can change is Distance to Empty (DTE). Some platforms, such as Ford Powerstroke and Mercedes Sprinter, support DTE recalibration using aftermarket plug-in modules, so DTE reflects your new tank size. Others, like many GM Duramax and Ram Cummins trucks, do not have straightforward options for updating their computer systems to recalibrate to the larger tank size at this time, so the DTE may under-estimate your real range.

Diesel weighs ~7–7.1 pounds per gallon. A 20–30 gallon increase means 140–210 pounds when full, well within payload margins for HD pickups, but worth planning around. This added weight rarely limits capability, but it’s important to factor it into payload calculations when towing or carrying heavy gear.

A larger tank gives you real-world payback in:

• Time saved avoiding fuel stops

• Better fuel pricing flexibility (Fuel price differences of $0.20 to $0.50 between stations can save $12–$30 on a 60-gallon fill)

• Smoother towing as greater range makes it easier to avoid small, crowded gas stations

• Greater freedom on long trips and off-grid adventures

Not only can a larger tank save on the cost of gas, but it also saves time, reduces travel stress and provides more freedom on the road.

Upgrading your range is only worth it if the tank you choose is engineered to last, integrates cleanly with your truck, and delivers reliability in the real world. S&B builds high-capacity replacement fuel tanks for drivers who tow hard, travel far, and rely on their trucks and vans every day. 

Here’s what sets S&B apart from other options on the market.

• Engineered for your exact platform — Every tank is designed around the precise mounting points, clearances, and fuel-system requirements of Powerstroke, Duramax, Cummins, Sprinter, and Revel platforms to ensure a true direct-fit upgrade.
  

• Crafted from premium ¼” thick, cross-linked polyethylene for life-long durability — S&B fuel tanks use a seamless, one-piece XLPE construction proven to resist impact, corrosion, and harsh environments. No welds. No seams. No rust. Built to last.
  

• Effortless installation, plug-and-play install — S&B’s fuel tanks mount precisely in the factory location and reuse the original fill neck and sending unit for a seamless upgrade. No cutting, no relocation of surrounding parts, and no hassle, just a straightforward installation built to last.
  

• Tested and proven for real-world towing, hauling, and off-road use — S&B designs and validates each tank for the conditions owners actually experience: vibration, heat, load cycles, rough roads, and long miles in demanding environments.
  

• Maintains OEM fuel gauge accuracy with DTE support where available — Because the factory sending unit is retained, fuel gauge readings remain dependable. Select Ford Powerstroke and Mercedes Sprinter applications also support DTE recalibration for more accurate range estimates.
  

Backed by S&B’s Million Mile Limited Lifetime Warranty for total confidence - Each tank is supported by long-term warranty protection and the same engineering commitment found across the vast majority of S&B’s lineup of performance products.

A high-capacity fuel tank isn’t just about having more fuel in your truck or van; it’s a smarter way to drive. By increasing range, cutting fuel stops, and giving you more control over when and where you fill up, an S&B high-capacity diesel fuel tank turns your truck into the long-haul tool it was meant to be, without sacrificing bed space, safety, or peace of mind.

Ready to spend more time driving and less time at the pump? Find the right S&B High-Capacity Fuel Tank for your diesel truck.

No. On supported platforms for S&B tanks, the OEM sending unit remains in the factory location, so fuel gauge readings stay accurate. 

DTE is calculated through on-board computer systems programmed by the manufacturer for the stock tank size. Replacing the stock tank with a larger capacity tank will result in inaccurate distance to empty readings. However, many Ford Powerstroke and Mercedes Sprinter platforms support recalibration with aftermarket plug-in modules like those offered by S&B, while most GM Duramax and Ram Cummins systems do not allow DTE adjustment. Even when DTE cannot be recalibrated, fuel level readings on the fuel gauge stay accurate.

Some platforms may see a minor reduction in clearance, typically engineered within safe tolerances for real-world use, off-road travel, and driveway breakover angles. S&B tanks are designed to maintain or closely match OEM clearance wherever possible.

No. In regularly driven vehicles, fuel turnover is healthy, and diesel does not degrade faster simply because the tank is larger. Normal driving cycles keep the fuel fresh, even in extended-range tanks.

Yes. S&B tanks use thick-wall cross-linked polyethylene, which resists corrosion, condensation, vibration, and impact. They retain all OEM emissions equipment and are engineered to be safe for heavy towing, long-distance travel, and off-grid use.

Many professional shops install S&B tanks in 2–3 hours, and experienced DIY owners with a jack or a lift can complete the upgrade safely. Because tanks interface with the fuel system, straps, and emissions lines, S&B recommends using proper tools and safety practices or choosing a qualified installer from S&B’s approved dealer network.