How To: Installing S&B Tanks’ 60-Gallon Fuel Tank for Ford’s 2011-2016 Super Duty

    S&B Tanks brings bolt-in maximum fuel storage to Ford’s Super Duty pickup trucks.

    KJ JonesAuthor

    Hopefully, you have already taken a moment to read our report on 5 large-capacity diesel fuel tanks. In that article, we highlight some of the popular styles and sizes, as well as typical reasons for adding bigger fuel cells, and what their benefits and drawbacks are.

    Extending the fuel range for Corben Guerra's 2011 Ford F-250 is our mission for this effort, so we're replacing the truck's stock 26-gallon fuel tank with S&B Tanks' 60-gallon replacement cell (for crew-cab, shortbed trucks).

    The injection-molded S&B tank is a direct bolt-in (no cutting, drilling, or body/chassis modifications are necessary), and, as we saw when we followed technician Will Gadzinski as he performed the installation at PSP Diesel in South Houston, it can be swapped into a Super Duty by DIY-motivated enthusiasts in approximately three hours. We like the sump that's incorporated into the cell, making it perfect for use with lift pumps and under hard-acceleration driving conditions.

    The straightforward process starts with performing basic steps such as draining fuel from the original tank, safely lifting the truck high enough to facilitate tank removal and replacement, taking off the skidplate and rear-bumper brackets, and disconnecting the vent and fuel-fill lines (at the chassis), the electrical harness for the fuel pump, and the feed/return lines. Once the brackets are out, the stock cell can be lowered and removed (Will muscled ours out, but working with a hydraulic transmission jack makes this task easier).

     

    Once the original tank is down, Will continues the process by taking the sending unit out and then preparing the S&B tank for installation. This includes making sure all is clear inside, setting an O-ring in its channel, dropping a new sending-unit float (included with the tank) in place and positioning a flange shim that separates the sending unit and locking ring that keeps it secured. Before the S&B tank is raised, PSP's team also replaced the hammered body mounts in Corben's F-250, using S&B's premium silicone-rubber bushings.

    Finally, original vent and fuel-fill hoses are transferred onto their respective fittings on the new tank (with the same orientation as stock, and they must go over the frame before the tank is in). Will then places a supplied U-bolt over the frame and, with assistance from another tech, raises the new tank into position—remembering to reconnect the wiring for the sending unit, and fittings for the fuel-return and feed lines, before bolting the tank in place with new straps.

    S&B Tanks' 60-gallon fuel tank for Ford's 2011-2016 Super Duty (it actually holds 56 gallons, but the rounded-up number sounds much better) is totally dialed in. From a fitment perspective, and despite its obvious larger size, the well-designed cell sits comfortably within the space created for the stock tank, not conflicting with the driveshaft, four-wheel-drive hardware, or even the aftermarket traction bars on Corben's rig.

    At the end of the day, installing S&B's tank is a reasonably easy project that can be accomplished by mechanically adept enthusiasts or trusted to professionals like Will at PSP Diesel. The net gain by adding one is a 30-gallon increase in fuel capacity, which is exactly what's necessary for long, nonstop trips.

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