Double Your 5th Gen 4Runner's Range Without Giving Up KDSS or Your Factory Tank

The 2010-2022 5th Gen 4Runner is built for the trail, especially on TRD Off-Road and TRD Pro trims with KDSS and factory air ride. The tradeoff is range: a loaded 4Runner on 33s burns through its factory tank fast once the pavement ends.

Jerry cans and roof-mounted fuel cells mean carrying gas exposed and pouring it by hand. A tank swap means pulling your factory tank and evap system. Neither is a great fit for a vehicle built around trail capability.

An Auxiliary Tank That Keeps Your KDSS and Air Ride

The Helivue Design 5th Gen 4Runner auxiliary fuel tank adds a second, 18 gallon tank alongside your factory tank, roughly doubling your fuel capacity. It tucks above the bumper line, keeping your KDSS, factory air ride, and Class 4 receiver hitch fully intact, and leaves your factory evap system untouched.

How the Tank Fills and Transfers Fuel

It fills through your factory filler neck, and both tanks fill at the same time, so there's no second gas cap or extra stop at the pump. When you want the extra fuel, a programmable transfer switch with a built-in level gauge moves it into your main tank. The kit includes a quality fuel pump, a stainless steel level sender, and all the stainless clamps, hardware, and bung you need.

Build, Specs, and Install

The tank is built from 1/8 inch 5052 aluminum for strength and corrosion resistance, weighs about 25 pounds empty, and holds 18 gallons - about 133 pounds full. It installs in the spare tire location, so you'll need a new home for your spare. Plan on about four hours for the install, or find a shop through our installer page.

Because this platform predates the frame-mount kits we build for newer trucks, vehicle prep involves more cutting: the spare tire carrier and its crossmember support are cut away, and the rear bumper foam is trimmed for tank clearance. The factory EVAP canister is relocated onto a supplied aluminum bracket rather than removed, which requires drilling new 13.5mm mounting holes and installing M8 rivet nuts with a rivet nut tool. The tank itself mounts the same way, with rivet nuts rather than through-bolts. As with our other welded-bung kits, the filler neck needs an actual weld, done off the vehicle, to install the threaded bung.

Designed, Built, and Tested in Colorado

Every tank is designed and built in Colorado, and our tanks have been beaten, bashed, landed on, and driven regularly at elevations from 5,000 to 13,000 feet without failure.

5th Gen 4Runner Auxiliary Fuel Tank FAQ

How much fuel does the auxiliary tank add?

It adds 18 gallons on top of your factory tank, roughly doubling the 4Runner's fuel capacity.

Do I keep my KDSS and air ride?

Yes. The tank tucks above the bumper line and doesn't touch your KDSS, factory air ride, or Class 4 receiver hitch.

Do I keep my factory fuel tank?

Yes. This is an auxiliary tank, not a replacement. Your factory tank and evap system stay in place.

Do I lose my spare tire?

The tank mounts in the spare tire location, so you'll need to relocate your spare, for example to a rear bumper carrier or bed mount.

How do I fill it?

Through your factory filler neck. Both tanks fill at the same time, so there's no second gas cap.

How long does the install take?

About four hours with basic tools. Prefer a shop? See our installer list.

What does the tank weigh?

About 25 pounds empty and about 133 pounds full.

Does the tank require any cutting?

Yes. On this platform, the spare tire carrier and its crossmember support are cut away, and the rear bumper foam is trimmed for tank clearance.

Does the EVAP system get removed?

No. The factory EVAP canister is relocated onto a supplied aluminum bracket rather than removed, so your factory evap system and emissions function stay intact.

Does the filler neck need to be welded?

Yes, an actual weld is required to install the threaded bung, done off the vehicle and off the tank.

How does the transfer switch and fuel gauge work?

The dash-mounted switch has a built-in LED gauge for the auxiliary tank. All green means full; the lights go dark from top to bottom as fuel transfers out, and a flashing red light means empty. Press the switch to start transferring fuel at about 0.42 gallons per minute. The pump runs for about six minutes per press and then shuts off automatically, so you just press it again if you want to keep transferring.

Will the Distance to Empty (DTE) function still work?

Yes, if your vehicle has it. It will report range based on the fuel level in the main tank only, since the factory computer doesn't see the auxiliary tank.

In Stock and Shipping Now

The 5th Gen 4Runner tank is in stock and shipping now. Use the vehicle finder at the top of our site to confirm fitment, or reach out with any questions.