The S&B Tanks 10-1002-1 is a direct-replacement 40-gallon aft-of-axle polymer fuel tank engineered for 1999–2010 Ford F-350, F-450, and F-550 Super Duty narrow-frame Cab & Chassis diesel trucks. Manufactured from premium high-density cross-linked polyethylene (XLPE), this rear-mounted replacement tank cures the severe factory steel tank lining delamination and rust issues on trucks utilizing the factory PS-123 fuel sending unit. S&B designs this tank to mount directly into the factory chassis frame crossmembers behind the rear axle, retaining the original sending unit, float arm, and fuel lines without requiring frame cutting or modification.

Severe steel tank liner delamination peeling off in sheets, micro-fine rust flakes clogging fuel filters, ruined low-pressure lift pumps, catastrophic failure of expensive high-pressure fuel injectors (HEUI and common rail systems), and rotted exterior steel tank seams from trapped road salt are what this tank permanently cures. The original equipment Ford 40-gallon steel aft-axle fuel tanks on 1999–2010 cab-and-chassis trucks are notorious for internal protective lining separation caused by modern ultra-low sulfur diesel (ULSD) and biodiesel blends. Once the factory coating delaminates, the peeling silver coating and underlying rust bypass primary suction screens, causing recurring fuel starvation, engine stalls, and thousands of dollars in fuel system destruction. S&B’s seamless, corrosion-proof XLPE construction is completely impervious to diesel fuel, condensation rust, and chemical delamination. It is a direct-replacement fuel tank and mounting strap kit only; the factory PS-123 fuel sending unit is reused, and auxiliary fuel pumps, sump kits, or replacement sending units are sold separately.

It fits 1999–2010 Ford F-350, F-450, and F-550 Super Duty Cab & Chassis models (Regular Cab, SuperCab, and Crew Cab) equipped with narrow rear frame rails (approx. 34-inch frame width), an aft-of-axle rear fuel tank, the factory PS-123 sending unit, and the 7.3L, 6.0L, or 6.4L Powerstroke diesel engine (does not fit standard pickup bed models with wide frame rails; for trucks using the PS-191 sending unit, see S&B 10-1002-2).

Fitment

• 1999–2003 Ford F-350 / F-450 / F-550 Super Duty Cab & Chassis 7.3L Powerstroke
• 2003–2007 Ford F-350 / F-450 / F-550 Super Duty Cab & Chassis 6.0L Powerstroke
• 2008–2010 Ford F-350 / F-450 / F-550 Super Duty Cab & Chassis 6.4L Powerstroke
• Fits Regular Cab, SuperCab, and Crew Cab Cab & Chassis models with narrow frame rails
• Direct replacement for factory 40-gallon aft-of-axle steel fuel tanks using PS-123 sending units
• Replaces Ford OEM part numbers XC3Z-9002-AA, 6C3Z-9002-BA, 6C3Z-9002-A, 6C3Z-9002-E, 6C3Z-9002-F, 3C3Z-9002-AA, and 5C3Z-9002-BB
• Constructed from seamless high-density cross-linked polyethylene (XLPE)
• Permanently eliminates OEM steel tank internal liner delamination and rust contamination
• Compatible with modern ultra-low sulfur diesel (ULSD) and biodiesel blends
• Includes heavy-duty powder-coated steel mounting straps, rollover vent valves, and hardware
• Reuses factory PS-123 fuel sending unit, float arm, and quick-connect fuel lines
• Direct-replacement polymer fuel tank and mounting strap kit only

Ensure the fuel tank is run down as close to empty as possible before beginning installation, park the truck on a solid level surface, and disconnect both negative battery cables. Support the factory aft-axle tank securely with a transmission jack or wide-cradle floor jack, loosen the fill neck hose clamp, remove the vent lines, and disconnect the sending unit wiring harness. Use quick-disconnect fuel line release tools to disconnect the fuel supply and return lines, unbolt the lower strap brackets, and lower the original steel tank down from the rear frame crossmembers. Remove the factory retaining lock ring, carefully lift out the factory PS-123 fuel sending unit, and thoroughly inspect the plastic fuel pickup foot ("duckbill") and pre-filter screen for trapped delaminated tank liner debris, replacing the screen or sender assembly if fouled or brittle. Clean the sending unit sealing flange, position a new Viton O-ring gasket onto the S&B tank, install the factory sending unit, and tighten the included heavy-duty locking ring. Raise the new polymer tank into place between the rear frame rails, install and torque the supplied heavy-duty mounting straps, reconnect the fuel lines, vent lines, and electrical harness, and add clean diesel fuel to verify airtight seals.