The Titan Fuel Tanks 8020099A is a direct-replacement 40-gallon high-capacity aft-axle polymer fuel tank engineered for 1999–2010 Ford F-350, F-450, and F-550 Super Duty Cab & Chassis diesel trucks. Built from military-grade cross-linked high-density polyethylene (XLHDPE) with a minimum 1/4-inch wall thickness, this direct-fit rear-mounted tank replaces the notorious factory steel aft-axle tank mounted behind the rear axle. Titan designs this tank to reuse the original chassis mounting position, factory fuel sending unit, float arm, and fuel lines, providing a permanent solution to factory fuel storage issues without requiring frame modifications.

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 infamous for internal lining separation caused by modern ultra-low sulfur diesel (ULSD) and biodiesel blends. Once the factory coating delaminates, the peeling silver lining and underlying rust bypass primary screens, causing recurring fuel starvation, engine stalls, and thousands of dollars in fuel system destruction. Titan’s seamless, corrosion-proof XLHDPE construction is completely impervious to diesel fuel, condensation, and chemical delamination. It is a direct-replacement fuel tank and mounting strap kit only; the factory fuel sending unit is reused, and auxiliary fuel pumps or 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 a factory aft-of-axle rear-mounted tank and the 7.3L, 6.0L, or 6.4L Powerstroke diesel engine (fits narrow cab-and-chassis frame rails; does not fit standard pickup bed models with wide frame rails).

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 equipped with an aft-axle fuel tank
• Direct replacement for factory 40-gallon aft-of-axle steel fuel tanks
• Constructed from high-density cross-linked polyethylene (XLHDPE) with 1/4" wall thickness
• 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 and low-profile rollover valve
• Reuses factory 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 as low as possible before starting the 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 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 Titan tank, install the factory sending unit, and tighten the included Titan heavy-duty lock 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.