Super Duty fuel tank upgrade


Transfer Flow 50-gallon replacement fuel tank nearly doubles 2011 Super Duties’ driving range

By Bruce W. Smith

Landscaper or construction worker, aggregates manager or bridge builder, most owners of heavy-duty pickups in the trades choose a diesel package over gas because it provides the best power for pulling trailers and hauling loads while delivering good fuel economy.

The latter equates to more time spent in the field and less at the fuel pump.

So the last thing you’d want to see in your new diesel pickup is a smaller fuel tank. But, alas, that’s exactly what’s happened underneath the 2011 Ford Super Duties.

Ford’s new 6.7L diesel is said to get about 20-percent better fuel economy than the engine it replaces. But instead of extending the driving range of the new trucks, Ford keeps it about the same by cutting the fuel tank size from 30.5-gallons to 26.  

That loss in fuel capacity just happens to be by the same amount as the 5.5-gallon Diesel Exhaust Fluid (DEF) reservoir that now sits just aft of  the fuel tank on F-250/350 Crew Cab 4x4s like our Project Super Crew.

Fortunately for those who want to stay on the road as long as possible between fuel stops, California-based Transfer Flow, Inc. has an immediate remedy: Replace the little OEM plastic fuel tank with a 50-gallon steel tank.

It’s an easy upgrade for any shop as demonstrated by Truck Supply & Outfitters (205-553-4203) when they installed one of the new fuel tanks (about $800), in our 2011 F-250 known affectionately as Project Super Crew.

Professional installer Daniel Parker completed the swap in about 90 minutes. He also sprayed the tank before installation with All Pro Lining’s spray-on coating to help keep it looking good over the long haul.

As you can see from the photos below, the fuel tank upgrade is simple, and doesn’t require any special tools other than a good transmission jack when using a hoist, or floor jack if a hoist isn’t handy.

Rest assured, Transfer Flow’s step-by-step installation instructions are very thorough, leaving nothing to chance.

Upgrading to the larger replacement fuel tank nearly doubles driving range, which means less time spent at the fuel pump and more time at the jobsite. That’s a win-win in our book.