School Bus Fuel Tank Replacement: Fitment Guide for Blue Bird, Freightliner, and IC Bus

School bus fuel tank replacement is not a straight swap. Capacity alone does not determine fitment. Strap spacing, fill neck position, and frame rail clearance all vary by make and configuration - getting any one wrong means the tank does not mount correctly. Always provide your OEM part number when ordering to confirm fitment before anything ships.

How Many Gallons Does a School Bus Fuel Tank Hold?

Capacity varies by make, model year, and whether the bus runs diesel or gas, but full-size school bus fuel tanks generally run 60 to 100 gallons. The common replacement sizes by make are:

• Blue Bird: 45, 60, 90, and 100 gallon.

• IC Bus (Navistar): 35, 60, 65, and 100 gallon.

• Freightliner and Thomas: 31, 35, 60, 62, 75, and 100 gallon.

Fill neck position and strap spacing change by configuration, so match a replacement to your exact make, model year, and capacity, not to the tank that looks closest.

School Bus Fuel Tank Replacement: Four Variables That Determine Fitment

These four variables must all be confirmed before ordering a replacement tank. Ordering on any single variable - especially capacity - is how a fuel tank comes back wrong.

1. Tank capacity - a capacity change typically changes overall dimensions as well

2. Overall dimensions (length, width, height) - determine whether the replacement fits the frame rail space

3. Strap spacing - the distance between mounting strap bands must match existing hardware exactly

4. Fill neck position and angle - must connect to the existing fill tube without modification

Which Fuel Tank Fits a Freightliner FS65?

The Freightliner FS65 is the most common Freightliner school bus chassis. Tanks mount outboard on the passenger-side frame rail with two strap bands. The 60-gallon and 80-gallon configurations are not dimensionally interchangeable - strap spacing differs between them.

Auto‑jet Part #	Fits	OE Number
FRLGT0458	Freightliner	6127-0458
FRLGT0470	Freightliner	6127-0470, 6127-0246
FRLGT6002	35 Gallon	A03-34726-002, A03-34726-002, 90RS1535CC-50, A03-34726-001, 03-34726-001, 03-34726-002, 03-37205-002, A03-37205-002
FRLGT7000	100 Gallon	A03-34727-000, 03-34727-000
FRLGT4675	Freightliner	TBB 164675
FRLGT9001	60 Gallon	03-42969-001
FRLGT7001	60 Gallon	A03-34727-001
FRLGT5001	60 Gallon	A03-37205-001
FRLGT0357	Freightliner and Thomas	6127-0357
FRLGT5000	100 Gallon	A03-37205-000, 03-34726-000
FRLGT4000	Freightliner and Thomas	A03-34334-000
FRLGT0471	Freightliner and Thomas	6127-0471
FRLGT2002	62 Gallon	A03-24712-002

• Standard 60-gallon FS65 tank: part FRLGT7001 - confirm OEM before ordering

• Some configurations ran 80-gallon - confirm original capacity from chassis spec sheet or measure strap spacing

Which Fuel Tank Fits an IC Bus?

IC Bus fuel tanks vary by capacity across model years. Confirm the exact OE number from the chassis data plate before ordering, since several capacities are available.

Auto‑jet Part #	Fits	OE Number
NAVGT24C93	65 Gallon	3556524C93, 3556524C92, 3596529C92
NAVGT34C92	65 Gallon	2586534C92
NAVGT25C92	65 Gallon	3556525C92
NAVGT30C91	65 Gallon	2041430C91
NAVGT10C92	100 Gallon	2017710C92, 3596530C92
NAVGT48C93	60 Gallon	2014748C93, 2507578C92
NAVGT74C91	35 Gallon	25075474C91
NAVGT07C92	Navistar International	2588007C92, 2586534C92
NAVGT69C91	100 Gallon	3566369C91
NAVGT79C91	65 Gallon	2507579C91

• 65 gallon: part NAVGT30C91 - call to confirm fitment by year

• 100 gallon: part NAVGT10C92 - call to confirm fitment by year

• Older units may show International or Navistar on the data plate - confirm OEM number either way

Which Fuel Tank Fits a Blue Bird School Bus?

Blue Bird Vision and All American mount the fuel tank at different chassis positions. The tanks are not interchangeable between body styles. Confirm body style from the chassis data plate before ordering, and provide the OEM part number to verify fitment for your specific year.

Auto‑jet Part #	Fits	OE Number
BBGT7342	90 Gallon	Call to confirm
BBGT7682	45 Gallon	Call to confirm
BBGT8146	60 Gallon	0068146, 10019906, 10049447, 15314177, 1667690
BBGT5138	100 Gallon	00067240, 10015138 10049444, 10063380, 10058732, 10063379
BBGT6000	60 Gallon	10015137, 00067239, 0067239, 10058060, 10058860, 0049389, 10049441
BBGT5137	60 Gallon	10015137, 0067239
BBGT7642	90 Gallon	1997642
BBGT5493	100 Gallon	1935493, 0068151
BBGT7716	60 Gallon	01667716, 0068148
BBGT7501	100 Gallon	1997501, 0049387

What to Confirm Before Ordering a School Bus Fuel Tank

Have this information ready before placing any fuel tank order. Photograph the installed tank before removal - strap positions, fill neck, and fuel line connections:

• OEM part number - most reliable confirmation method

• Bus make and chassis model (chassis data plate)

• Original tank capacity in gallons

• Strap spacing - measure between the two mounting band centers

• Fill neck position and angle

• Model year

Call 800‑247‑5391 or contact our team with your bus make, OEM part number, and strap spacing to confirm fitment.

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Frequently Asked Questions

Can I replace a 60-gallon school bus fuel tank with an 80-gallon tank?

Not without confirming strap spacing, fill neck position, and frame rail clearance. Capacity changes often come with dimensional changes that affect fitment. Confirm all three before ordering a different-capacity replacement.

What causes a school bus fuel tank to need replacement rather than repair?

Seam corrosion that cannot be sealed, strap mounting flange failure, and structural cracks from impact or fatigue are the primary reasons. A leaking tank near the frame rail or fuel system components is a safety issue and requires replacement, not patching.