International DuraStar Fuel Tanks

Frequently Asked Questions About International DuraStar Fuel Tanks

What year models of International DuraStar are these fuel tanks compatible with?

Our International DuraStar fuel tanks are designed to fit model years 2002 through 2018. The mounting brackets and strap configurations vary between the 2002-2007 models and the 2008-2018 models, so make sure to select the correct tank for your specific year. Pre-2008 models use a different strap mounting system, while 2008 and newer models feature an updated bracket design. Always verify your OEM and model year before ordering to ensure proper fitment.

What material options are available and which is best for my application?

We offer both aluminum and steel fuel tanks for the DuraStar. Aluminum tanks are lighter (reducing overall vehicle weight by 40-60 pounds), resist corrosion better, and are ideal for trucks operating in salt-heavy regions or coastal areas. Steel tanks are more budget-friendly and offer excellent durability for standard highway use. Most owner-operators prefer aluminum for the weight savings and longevity, while fleet operators often choose steel for the lower upfront cost. Both materials meet DOT specifications and come with appropriate mounting hardware.

Can I install a larger capacity tank than my original, and what modifications are needed?

Yes, you can upgrade to a larger capacity tank, with options ranging from 50 to 150 gallons depending on your DuraStar chassis configuration. However, tanks over 100 gallons may require relocating the DEF tank on 2010 and newer models, and you might need extended fuel tank straps. The frame rail spacing on DuraStar models allows for various tank sizes, but measure your available space carefully - typical clearance needed is 26 inches for 100-gallon tanks and 30 inches for 150-gallon tanks. Additional brackets or crossmember modifications are rarely needed unless going from a single to dual tank setup.

What tools and time investment should I expect for installation?

Installation typically takes 2-4 hours for experienced mechanics and 4-6 hours for first-timers. Essential tools include a floor jack or transmission jack to support the tank, 3/4 inch and 7/8 inch wrenches for the mounting straps, fuel line disconnect tools, and basic hand tools. You will need to drain the existing tank completely before removal. The most challenging part is usually disconnecting the fuel sending unit wiring harness, which requires careful handling to avoid damage. Many customers report the hardest step is aligning the new tank while reconnecting fuel lines, so having a helper makes the job significantly easier.

Do these tanks come with sending units, and are they compatible with my gauge?

Most replacement tanks come without sending units, as these components typically transfer from your old tank. The sending units from 2002-2018 DuraStar models are generally interchangeable within the same tank depth. However, if your sending unit is damaged or reading incorrectly, we recommend replacing it during tank installation. Standard 5-bolt pattern sending units fit all our DuraStar replacement tanks. For 2010 and newer models with digital dash displays, ensure your sending unit is the 0-90 ohm type for accurate fuel level readings.