Kenworth Cabover Fuel Tanks

Frequently Asked Questions About Kenworth Cabover Fuel Tanks

What fuel tank sizes are available for Kenworth cabover models, and how do I know which one fits my truck?

Kenworth cabover fuel tanks typically range from 50 to 150 gallons, with 100-gallon tanks being the most common for K100 and K100E models. To determine the correct size for your truck, check your door jamb sticker for the original tank specifications or measure your existing tank's dimensions (length x diameter). Most K100 models from 1963-1986 use 25-inch diameter tanks, while later K100E models (1987-2010) may use 23-inch or 25-inch diameter tanks depending on the configuration.

Are these fuel tanks made of aluminum or steel, and which material is better for my application?

Both aluminum and steel options are available. Aluminum tanks are lighter (reducing overall vehicle weight by 50-100 pounds), resist corrosion better, and are ideal for trucks operating in coastal areas or regions using road salt. Steel tanks are typically 20-30% less expensive, more resistant to impact damage, and easier to repair if punctured. For long-haul applications where weight savings matter, aluminum is preferred. For vocational trucks or budget-conscious operators, steel remains a solid choice.

Can I install these fuel tanks myself, or do I need professional installation?

While experienced mechanics can install these tanks, professional installation is recommended due to DOT regulations and safety requirements. Installation typically takes 3-4 hours and requires proper mounting straps, anti-rotation brackets, and fuel line connections. You'll need to ensure proper grounding for steel tanks and may need to relocate crossmembers on some models. Most importantly, improper installation can void warranties and create dangerous conditions, so factor in $200-400 for professional installation when budgeting.

Do these replacement tanks come with mounting hardware and fuel sending units?

Most replacement tanks come as bare units without mounting hardware or sending units. You'll need to purchase mounting straps, bushings, and hold-down bolts separately (typically $75-150 for a complete mounting kit). Fuel sending units must be ordered based on your specific gauge type - Stewart Warner, VDO, or Datcon systems require different ohm ranges. Some suppliers offer complete tank packages that include all necessary components, which can save time and ensure compatibility.

What's the difference between round and D-shaped fuel tanks for Kenworth cabovers?

Round tanks are the standard configuration for most Kenworth cabovers and mount using traditional strap systems. D-shaped (or rectangular) tanks offer 10-15% more capacity in the same space and sit flush against the frame rail, providing better ground clearance and a cleaner appearance. D-shaped tanks require specific mounting brackets and are typically found on newer K100E models or custom applications. Round tanks are generally more affordable and easier to find, while D-shaped tanks maximize fuel capacity for long-haul operations.