School Bus Fuel Tank Replacement: Fitment Guide by Bus Make and Tank Size
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School Bus Fuel Tank Replacement: What to Check First
School bus fuel tanks are replaced for two reasons: corrosion and impact damage. Corrosion at the bottom seam or at the tank straps is the most common failure mode, especially on buses over ten years old.
Tank Sizes by Bus Make
Fuel tank capacity varies by bus make, body style, and route configuration. Confirm the gallon rating before ordering — same bus model sometimes came with different tank size options.
Blue Bird Vision and All American: 60, 80, or 100-gallon depending on body length and route spec
Thomas Built Saf-T-Liner HDX: 60 or 80-gallon — confirm body length
Freightliner FS65: 80-gallon standard for most configurations, 62-gallon also available
IC Bus CE Series: 60-gallon standard, 80-gallon available for extended-body spec
Auto-jet stocks direct-fit replacements for all configurations listed above. Two of the most commonly replaced:
Auto-jet # BBGT6000
Auto-jet # FRLGT2002
Q: How do I know if I need a 60 or 80-gallon tank?
A: Check the original spec sheet or the tank itself — capacity is typically stamped or labeled on the tank. If it's not visible, call us with the bus make, body style, and model year.
Strap and Mount Condition
Replacing just the tank without inspecting the straps is a common mistake. If the straps are corroded, they'll fail and drop the new tank. Replace straps when you replace the tank.
Q: Can I reuse original tank straps when replacing the fuel tank?
A: Inspect them first. If there's any surface corrosion that has pitted into the strap material, replace them. Straps that held a deteriorated tank have been under stress and may be compromised.