OK, THE RESULTS ARE IN.
It turns out that our 32 gallon tanks have...........32 gallons of Useable Capacity.
I made it 2.5 days riding around on "Low fuel" with the needle buried below E before the motor quit. To Make this clear- I intended to run out of fuel, and was carrying 1 gallon with me and sticking to non-highway driving to minimize the hazard I could create, thankfully it happened not only in a safe area, but an empty road, and within sight of a Sunoco. After refueling with the 1 gallon reserve and resetting the trip meter, I clocked 0.4 miles in 1:44 of 'engine running' time before pumping 31.2 gallons in. The reserve can took an additional 1.03 gallons. No fuel spilled over through any vents or the neck and I let it pop off twice with a 30 second pause in between.
I have been beating on my truck for the past several days trying to suck down the fuel, and my average economy slipped down from 18+avg to 16.6mpg avg. The Range after refilling showed 514 miles.
514miles/32gal=16.0625mpg vs the displayed 16.6mpg so that is well within a range of accuracy that I would consider acceptable, considering the Range calculation is dynamic and reliant upon your driving habits, and mine had just changed dramatically in the last 100 miles....which is a more than a coincidence as the 6 gallon difference between the 26 and 32 gallon options nets out 99.6 miles of additional range (6gal x 16.6mpg= 99.6 miles.)
If your reading this and saying 'What a useless test, who friggin cares" I can't necessarily argue with you, there are so many variables (drivetrain variations/city/hwy/towing/winds/heavy right foot, etc...)that could affect your situation, we're still going to drive the truck and its still SAFEST to refuel when the obc says its time. But, maybe you don't need to be late to your daughters piano recital because you thought you were going to have to push the truck there if you didn't stop and refuel when the low fuel warning illuminated.
So, in conclusion. we actually do have 32 gallons useable! and it would seem the computer in my truck is ABSOLUTELY calibrated for a 26 gal tank regardless of the trucks build, and STAR Case# S1608000283 acknowledges this.