Frequently Asked Questions About International WorkStar Fuel Tank Accessories

What size fuel tanks are compatible with my International WorkStar, and how do I determine the correct capacity?

International WorkStar trucks typically accommodate fuel tanks ranging from 50 to 150 gallons, depending on your model year and chassis configuration. To determine the correct capacity, check your door jamb sticker for the original tank specifications or measure your existing tank's dimensions (length x height x width). WorkStar models from 2008-2017 commonly use 25" or 26" diameter tanks, while newer models may vary. Always verify your frame rail spacing before ordering, as this directly impacts which tank sizes will fit properly.

Are aluminum or steel fuel tanks better for my WorkStar, and what gauge thickness should I look for?

Aluminum tanks are lighter (reducing overall vehicle weight by 50-100 lbs) and resist corrosion better, making them ideal for trucks exposed to road salt or coastal environments. Steel tanks cost 20-30% less and offer superior impact resistance for off-road applications. For durability, look for aluminum tanks with .125" (1/8") thickness minimum, or steel tanks with 14-gauge (.075") thickness. Most WorkStar owners in construction or heavy hauling prefer aluminum for the weight savings and longevity.

What mounting hardware and brackets do I need to install aftermarket fuel tanks on my WorkStar?

A complete installation requires tank straps (typically 3" wide for WorkStar applications), mounting brackets specific to your frame width, rubber isolators to prevent metal-on-metal contact, and grade 8 bolts with lock washers. Many WorkStar models use a 34" frame rail spacing, but always measure yours first. You'll also need fuel line fittings (usually 3/8" or 1/2" NPT), a sending unit compatible with your gauge cluster, and potentially a crossover kit if installing dual tanks. Budget 3-5 hours for installation with basic tools.

Will aftermarket fuel tanks work with my WorkStar's existing fuel gauge and DEF system?

Most quality aftermarket tanks include provisions for OEM-style sending units that maintain compatibility with your factory fuel gauge. For 2010 and newer WorkStar models with DEF systems, ensure your replacement tank has the proper auxiliary ports and heating elements if originally equipped. Some aftermarket tanks require sending unit calibration or gauge cluster programming, particularly when changing tank capacity. Tanks with SAE J1810 standard sending units typically offer the best plug-and-play compatibility.

What's the typical lifespan of fuel tank straps and anti-siphon devices on WorkStar trucks?

In normal conditions, quality fuel tank straps last 7-10 years, but trucks operating in high-salt environments may need replacement every 4-5 years. Look for straps with zinc plating or powder coating for maximum longevity. Anti-siphon devices, increasingly important for fleet operators, typically last the life of the tank when properly installed. Choose locking fuel caps rated for at least 5 PSI pressure and anti-siphon valves that don't restrict flow below 15 GPM to avoid refueling issues.