Frequently Asked Questions About Kenworth T800 Fuel Tank Senders

What years and models of Kenworth T800 are these fuel tank senders compatible with?

Most aftermarket fuel tank senders fit Kenworth T800 models from 1987 through 2007. However, compatibility can vary based on your specific tank configuration. Models with dual tanks, step tanks, or custom tank setups may require different sender lengths. Always verify your tank depth and mounting style (5-hole or 6-hole pattern) before ordering. If you're unsure, measure from the top of your tank to the bottom and compare with the sender specifications listed on each product page.

How difficult is it to replace a fuel tank sender on a T800, and what tools do I need?

Replacing a fuel tank sender typically takes 1-2 hours and requires basic hand tools. You'll need a socket set (usually 7/16" or 1/2"), screwdrivers, and potentially a brass drift punch to avoid sparks. The main challenges include safely draining the tank below the sender level, dealing with corroded mounting bolts, and ensuring proper gasket seal on reinstallation. Many drivers recommend having a new gasket on hand as the old one often tears during removal. Always disconnect the battery and follow proper safety procedures when working with fuel systems.

What's the difference between 0-90 ohm and 240-33 ohm senders, and which one do I need?

The ohm rating must match your truck's gauge cluster specifications. Most 1987-1999 T800s use 240-33 ohm senders, while 2000-2007 models typically use 0-90 ohm units. Using the wrong ohm rating will cause inaccurate fuel readings or gauge malfunction. Check your owner's manual or look for a label on your existing sender. If you can't determine the correct type, a qualified technician can test your gauge cluster to confirm the required ohm range.

Why is my new fuel sender giving inaccurate readings after installation?

Inaccurate readings usually stem from three main issues: incorrect sender arm length for your tank depth, improper ground connection, or gauge calibration problems. Ensure the sender arm isn't hitting the tank bottom or sides when moving through its full range. Check that the mounting surface is clean metal-to-metal contact for proper grounding. Some aftermarket senders may require arm adjustment or bending to match your specific tank geometry. If readings remain erratic, verify wiring connections and consider having your gauge cluster tested.

What's the typical lifespan of a fuel tank sender, and what causes them to fail?

Quality fuel tank senders typically last 5-10 years depending on operating conditions. Common failure causes include sulfur contamination from diesel fuel wearing the resistor strip, corrosion of electrical connections, and mechanical wear of the float arm pivot. Symptoms of a failing sender include erratic gauge readings, gauge stuck on full or empty, or intermittent operation. Regular use of fuel additives and keeping tanks above quarter-full can help extend sender life by reducing condensation and contamination exposure.