Titan 62-Gallon Replacement Tank and 30-Gallon Spare Tire Auxiliary Fuel System Tank - Diesel Tech

Nobody truly enjoys stopping for fuel. From the nasty pumps to the painful bill, it's a necessary evil most could do without. This notion is especially true for those who tow frequently. Fortunately, there is a solution that can make these hurtful experiences less frequent, without losing precious bed space.

Titan Fuel Tanks is a leader in the industry, providing upsized fuel tanks that fit snugly under all of the Big Three's heavy-duty truck lines. Built from extra-heavy-duty, cross-linked polyethylene, these tanks are sturdy enough to outlast the vehicle to which they are bolted. Each tank comes with the appropriate mounting hardware, hoses, wires, valves, and clamps for a complete installation.

For our 2008 Chevy Silverado 3500HD Crew Cab longbed, Titan offers a 62-gallon replacement tank and a 30-gallon Spare Tire Auxiliary Fuel System tank. This gives our truck a combined 92 gallons of fuel, and more than 1,000 miles of range between fill-ups. Even though the bill will be higher and sting a bit more, fuel payments will happen a third as often. And for a truck that regularly sees towing duty, not needing to stop for fuel with the trailer attached can be a big relief.

We headed down to Bud's Diesel in Midway City, California, where the crew got to work installing the pair of tanks under our dualie. Follow along with us as we nearly triple this heavy hauler's fuel-carrying capacity.

The new Titan 62-gallon fuel tank reuses the factory fuel pickup and sending-unit assembly. Before removal from the stock tank, this area should be thoroughly cleaned of dirt and debris to prevent contamination.

Before assembly, the new tank is checked for foreign objects and given a quick cleaning. A new O-ring is provided to seal the fuel pickup to the tank and should be lubed with a petroleum-based grease before tightening.

The Titan fuel tank is designed to accept the factory fuel pickup and fuel-level sending unit without any modification needed. This ensures there are no odd dash lights or trouble codes, and that the fuel gauge works as intended.

Special care was taken when removing the factory filler-neck tube, as this part is reused on the new tank. Damage to the filler can cause leaks or a "check engine" light, and fillers can be costly to replace.

New hoses and T's are supplied to provide adequate ventilation from the front and rear of the extra-long tank. These are in addition to, and splice inline with, the factory vent hoses.

Once the new Titan tank was wiggled into place, Neil went to work securing it. The tank mounts with the factory steel straps and a provided crossmember. The new crossmember bolts to both of the truck's framerails and supports the front of the tank.

With the 62-gallon main tank installed, Neil turned his attention to the 30-gallon Spare Tire Auxiliary Fuel System, also from Titan. Before slinging the tank into place, all the necessary hoses and wires were attached. Fortunately, Titan does an excellent job of providing everything that's needed.

The spare tire auxiliary tank weighs in at a svelte 30 pounds, making it possible for Neil to sling it into place. Holding the tank in place is a plate system that bolts in place of the factory spare tire winch.

Here we can see the plate that secures the Spare Tire Auxiliary Fuel System. Once the nut was torqued to spec, Neil moved on to wiring and plumbing the second tank.

A small, inline electric fuel pump is used to transfer fuel from the spare tire auxiliary tank to the main tank. We chose to mount the pump and filter to a bed floor support rib, which allowed us the most direct and kink-free hose routing.

The most painful part of the install is drilling the massive hole necessary to mount the auxiliary filler. We chose the inside of the bed for the most inconspicuous placement possible, however, the instructions offer up a template for bedside mounting as well.

Initiating the transfer of fuel from the auxiliary tank to the main tank is done at the push of a button on the dash-mounted controller. The controller also has the ability to display the fuel level in the auxiliary tank, ensuring you are not just pumping air.

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