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Auxiliary Fuel Tanks – Transfer Systems, Pumps, Controllers & Protection
Auxiliary fuel tanks add range by storing fuel in a second tank and transferring it to your main tank via an electric pump and controller. They’re ideal for remote routes where resupply is scarce, letting you balance weight and refill on demand. Choose a vehicle-specific kit, match capacity to your trips, and integrate vents, rollover valves and skid protection for safe touring.
In this section: Browse all categories • Aux Tanks – Quick Comparison • Capacity, Fitment & Compatibility • How to Choose • Care & Durability • Upgrade Sequence Roadmap • Related Sections • FAQ
Key Features
- 30–90 L typical added capacity in underbody or tray locations
- Electric transfer pump with dash switch or smart controller
- Vehicle-specific brackets, OE-style mounts and hose routing
- Sender/gauge options or status LEDs for transfer monitoring
- Proper vents, rollover valves and EVAP-friendly hardware (petrol)
Quick Comparison – Auxiliary Tank Options
| Style | Capacity (typ.) | Install | Control | Best For | Notes |
|---|---|---|---|---|---|
| Underbody Vehicle-Specific | 30–70 L | Bolt-in brackets | Dash switch/LEDs | OEM-like integration | Check spare wheel & towbar clearance |
| Rear/Behind-Axle | 40–90 L | Brackets + guards | Timed/auto-stop | Long-range touring | Mind departure angle & skid protection |
| Tray/Canopy (UTE) | 40–110 L | Tray mounts | Manual switch | Work/expedition utes | Securely vented; weight over axle |
| Polymer Lightweight | 30–60 L | Bolt-in | Basic switch | Weight-conscious builds | Add guards near heat/rocks |
| Stainless/Steel | 40–90 L | Bolt/weld-in (model dep.) | Smart controller | Harsh climates | High corrosion/impact resistance |
Buyer’s Checklist – How to Choose
- Calculate range for worst-case consumption and add 15–20% buffer
- Pick location: underbody for OEM look; tray/canopy for easy service; rear tanks need skids
- Choose controller: simple switch, timed transfer or auto-stop with indicators
- Confirm EVAP/vent compliance on petrol; proper rollover valves on all
- Verify clearances: spare wheel, towbar, exhaust heat, shocks and lines
Capacity, Fitment & Compatibility
Match the system to your platform and electrical/plumbing requirements.
- Electrical: fused feed, relay if required, quality earths; dash indicator for pump status
- Plumbing: fuel-rated hoses, clamps, filters and secure routing away from heat and moving parts
- Fillers: shared vs separate filler necks; ensure anti-splash and correct vent tie-ins
- Gauging: some kits add a sender/LED bar; others rely on transfer timers
- Protection: skids/stone guards for exposed positions; consider rock strike zones
Care & Durability
- Inspect mounts, hoses and clamps after rough tracks; re-torque hardware
- Test transfer function and indicators before trips; carry spare fuses
- Replace filters per schedule; drain contamination if a drain plug is provided
- Rinse mud/salt; touch up coatings on steel components
- Check vents/rollover valves for blockages; verify EVAP integrity (petrol)
Upgrade Sequence Roadmap
- Select an auxiliary tank sized to your route and load
- Add a smart controller with level/status indicators
- Fit skid/stone guards and heat shielding where needed
- Use quality hoses/filters and secure electricals with proper fusing
- Pair with a replacement main tank for maximum total capacity (if required)
Related Sections
FAQ – Auxiliary Fuel Tanks
- How does an auxiliary tank system work?
- An electric pump moves fuel from the aux tank into your main tank on demand, controlled by a dash switch or smart controller with status indicators.
- Is an auxiliary tank legal for road use?
- Vehicle regulations vary by region. Use compliant components, integrate EVAP on petrol vehicles and follow manufacturer guidance for venting and rollover protection.
- How much capacity should I add?
- Common additions are 30–90 L. Size it to your worst-case fuel burn and resupply gaps, then add a 15–20% buffer.
- Do I need a separate filler neck?
- Some kits share the main filler with internal routing; others add a dedicated filler. Separate fillers can simplify plumbing but need careful venting and sealing.
- Will an auxiliary tank affect departure angle?
- Rear/underbody tanks can. Check clearances with towbar, spare wheel and consider skid plates for rock protection.
- What about petrol vs diesel installs?
- Petrol requires EVAP-safe hardware and careful sealing. Diesel is more tolerant but still needs proper vent routing and rollover valves.
- Can I install it myself?
- Experienced DIYers can handle bolt-in kits, but professional installation ensures correct plumbing, wiring, EVAP integration and compliance checks.
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