While do-it-yourselfers can do a tank swap if they have the right tools, most of Aero's customers have the installation done at the factory. That may be because the warranty on a factory job is slightly better-three years and 50,000 miles versus two years and 30,000 miles on a DIY install.
Our particular application on a '96 Dodge Ram required some custom work in order to clear the mounting plate for a Gear Vendors gear-splitter. For a modest extra charge, Aero can custom-weld a tank with a recessed area to make room. Even with this modification, the tank capacity went from 36 gallons for the stock unit to nearly 60 gallons in the underbody tank. The 12-valve Cummins in this truck typically consumes 19 mpg on the highway, so that's more than a 1,000-mile range between fill-ups.
Here's one other point to consider when changing out the tank: the sending unit on the fuel pickup assembly on older Dodges is known for wearing out in as little as 40,000 miles, and that was the case on this truck. Remembering to reset the trip odometer at fill-up time (in order to estimate the fuel level by miles traveled) was getting annoying, so we were really glad that Jake Jacobs at Aero swapped out the sending unit with a newer type made of a more durable material.
Jacobs points out one difference in the gauge readout after upgrading to a larger tank. The fuel needle will stay on full for the first 15-20 gallons because Aero uses the factory fuel pickup and does not make any adjustments to this part. But look at it this way, even if you're not actually improving your fuel efficiency, it at least seems like you're getting more miles to the gallon!
 Two-part epoxy adhesive is...  Two-part epoxy adhesive is used to seal the top tank. Use caution not to get any on the locking ring or you'll never be able to open the tank if you need to. |  Use a floor jack and at least...  Use a floor jack and at least one assistant to raise the tank into place. Attach the original filler-neck hose, vent, and fuel lines to the Aero tank fittings. |  Drill bolt holes in the mounting...  Drill bolt holes in the mounting flanges, and through-bolt the tank to the truck's framerails. Use the mounting tabs as a guide to drill holes for the mounting bolts. No thin straps to rust or snap here! Once the tank is secured, transfer any remaining fuel in the old tank to the new one. |
 With 60 gallons in reserve,...  With 60 gallons in reserve, we're ready for 1,000 or more miles of nonstop cruising! Now we can shop around for the best price on diesel and take advantage of truck stops and rural fuel pricing. |  Aero manufactures all of its...  Aero manufactures all of its tanks in-house and can accommodate requests for custom setups. Prior to installation and painting with enamel, the factory replacement tanks are pressure-tested with a compressed air hose. | |