Adding More Range To Our 20-MPG 2007 Dodge Ram

1000 Miles To Empty 2007 Dodge Ram Mega Cab At Gas Station

When we recently had the option to equip our 6.7L Cummins-powered ’07½ Dodge Ram Mega Cab with one of Titan’s XXL 52-gallon fuel tanks, we jumped at the chance. Increasing our range, having the ability to fill up with cheaper fuel when we find it, not cluttering our bed with an external transfer tank, and replacing the stock tank with an OE-quality polyethylene unit that’ll never rust? That’s a no-brainer. With the factory tank pulled, we also decided to take advantage of the easy access and made some other modifications to the 6.7L Cummins’ fuel system in order to optimize the injection system’s durability, as well as support more power-adders in the future.

1000 Miles To Empty 2007 Dodge Ram On Lift

We brought our Dodge and components down to Diesel Tech in San Jacinto, California, for the install. Technician David Briggs racked our Dodge and got busy underneath yanking the stock tank. The factory fuel pickup line from the tank to the rear of the stock fuel filter canister was removed. Thanks to careful parts selection, we were able to retain the factory fuel return line.

We brought our Dodge and components down to Diesel Tech in San Jacinto, California, for th

Fuel Air Separation System’s (FASS) Platinum 95 system (PN P-D07-095G) was best for our needs and came with everything required for the installation. During the install (and in order to avoid drilling into our brand-new Titan fuel tank), we opted to run one of Vulcan Diesel Performance’s Jeep Liberty fuel modules for our in-tank pickup needs (as opposed to the suction tube supplied with the FASS system). Vulcan’s fuel module is equipped with one of its ½-inch Draw Straw II assemblies. This gave us peace of mind because it ensures a constant reservoir of fuel at low tank levels. In short, the Draw Straw-equipped Liberty canister makes installing a FASS or other aftermarket pump in a ’98½ to ’08 Dodge a slam dunk. Read on to see everything else we upgraded in our fuel system.

1000 Miles To Empty Installing The Fuel Pickup

The Vulcan Draw Straw-equipped Liberty canister is a big part of why our installation was so easy. With its ½-inch pickup tube located inside the canister (where the fuel return dumps), it allows for a constant reservoir of fuel to draw from. The Liberty sending unit employs the same ohm readings as the factory Ram sending unit, so our fuel gauge function remains unchanged.

The Vulcan Draw Straw-equipped Liberty canister is a big part of why our installation was

Mileage Report
To make the title of this story a reality and not just a catchy cover blurb, we set out to see if we could actually rack up 1,000 miles between fill-ups. With a 52-gallon-capacity fuel tank in our truck, we’d need to average 19.23 mpg. That’s obtainable on the highway, but with all the mileage-killing emissions equipment in place, we had to dig deep into our bag of tricks. Mileage testing began before the actual installation and consisted of between 1,500 to 2,500 miles of hand-calculated, GPS-verified number crunching for each finding. Here’s how it ran down:

Baseline specs:

Stock 6.7L engine
Stock 68RFE transmission
S&B cold-air intake
Dynatrac Free-Spin hubs
285/75R17 Toyo tires
Snugtop shell
Stock fuel system
Average Fuel Economy: 17.5 mpg

With Current Modifications:

Titan XXL 52-gallon tank
FASS Platinum 95
Glacier Diesel Power MK-2 and Big Line fuel system
Bully Dog Triple Dog GT tuner set to Tow mode
Replaced tires with shorter, lighter 285/70R17 BFGoodrich Rugged Terrains

Average Fuel Economy: 20.0 mpg
Distance to Empty = 1,040 miles

The Titan XXL fuel tank for Dodge Mega Cabs (PN 7030206) uses virtually all available space between the transfer case and rear axle to squeeze in 52 gallons of fuel-holding capacity. Dodge longbed, Quad Cab applications (PN 030303) hold 55 gallons.
The Titan XXL fuel tank for Dodge Mega Cabs (PN 7030206) uses virtually all available spac
The FASS Platinum 95 (PN P-D07-095G) came with all the fittings, mounting hardware, plug-and-play wiring harness, and other components you see here. The unit is designed to be installed without buying any additional components and included a 1/2-inch-diameter steel pickup tube, a fuel return that splices into the factory fuel fill hose, and a Push-Lok fitting for the CP3 fuel line that we didn’t use. Note the Napa Gold high-flow pre-filter (PN 3270) must be plumbed between the tank and FASS lift pump.
The FASS Platinum 95 (PN P-D07-095G) came with all the fittings, mounting hardware, plug-a
Before installing the Titan fuel tank, Briggs assembled the mounting hardware for the FASS pump so he could get an idea of where the unit would best be positioned. The pump needed to be placed before the tank was installed so the pump-to-filter lines could be run along the inner framerail.
Before installing the Titan fuel tank, Briggs assembled the mounting hardware for the FASS

The FASS pump includes a super-simple, plug-and-play wiring harness that connects in-line with the factory wiring at the in-tank fuel canister. Briggs hooked the positive and negative power leads directly to the driver-side battery then ran the wire loom back along the framerail and plugged it in-series to the stock canister connector. This way, the factory ECU turns the FASS pump on just as if it were the stock in-tank lift pump. No cutting or splicing of any factory wiring was required.
The FASS pump includes a super-simple, plug-and-play wiring harness that connects in-line
After determining the FASS pump mounting location on the framerail, Briggs drilled the mounting holes and bolted the pump in place using the supplied self-tapping hardware. He then built the 3⁄8-inch pickup line to rough size and connected it to the Vulcan Draw Straw pickup in the Liberty canister. A factory-type fitting with a 3⁄8-inch barbed end was used to attach the fuel return line from the FASS pump to the factory pickup fitting on the Liberty canister.
After determining the FASS pump mounting location on the framerail, Briggs drilled the mou
With the FASS pump mounted, the electrical connections completed, and the FASS pump-to-filter line run alongside the inner framerail, the tank could now be installed. Briggs began by lining the Titan tank straps with the supplied rubber insulation and placing them in the factory locations before lifting the tank into place.
With the FASS pump mounted, the electrical connections completed, and the FASS pump-to-fil

With the tank in place, the pickup and return lines were cut to exact length, the Push-Lok fittings were installed on the pump end of the hoses, and everything was buttoned up. FASS includes enough high-quality 3⁄8-inch fuel line to avoid making any sharp bends that could kink the line and hamper fuel flow.
With the tank in place, the pickup and return lines were cut to exact length, the Push-Lok
We also installed an MK-2 filter and Big Line kit from Glacier Diesel Power, which ensures a full 3⁄8-inch fuel supply from our tank to the CP3. All necessary hardware to mount the 2-micron Fleetguard filter and base was included. The laser-cut bracket essentially mounts the filter to the Cummins’ cylinder head yet still allows ample access to the power steering pump reservoir.
We also installed an MK-2 filter and Big Line kit from Glacier Diesel Power, which ensures
The only thing left to do was connect the FASS output line to the factory fuel filter canister. Glacier Diesel Power once again had the correct high-flow adapter fittings to replace the factory banjo bolt and line with high-flow 3⁄8-inch Push-Lok. In this case, we used its adapter fitting (PN 6MJICx12x1-5) and Cummins banjo gasket (PN 396983) to mount the 90-degree -6 AN fitting (PN 33982-6-6). After that, we tossed a couple of gallons in the tank, primed the fuel system, and opened the water drain on the Donaldson filter to help bleed off any air. The Cummins fired up in short order, and we were ready for our first 52-gallon fill-up.
The only thing left to do was connect the FASS output line to the factory fuel filter cani

SOURCES
Bully Dog 2839 Highway 39 American Falls ID 83211 866-285-5936 www.bullydog.com	Titan Fuel Tanks P.O. Box 2225 Idaho Falls ID 83403 208-522-1325 www.titanfueltanks.com
Diesel Tech 1685 S State St. San Jacinto CA 92583 951-766-5777 http://www.dieseltech1.com/	Glacier Diesel Power 509-993-4923 www.glacierdieselpower.com
BFGoodrich P.O. Box 19001 Greenville SC 29602 877-788-8899 www.bfgoodrichtires.com	Vulcan Diesel Performance 360-450-4237 www.vulcanperformance.com
Fass 4302 E Congress Ave Spokane WA 99223 866-379-8685 www.fassride.com