Kenworth T800 Fuel Tanks

Frequently Asked Questions About Kenworth T800 Fuel Tanks

What size fuel tanks are available for my Kenworth T800, and how do I determine the right capacity?

Kenworth T800 fuel tanks typically range from 50 to 150 gallons per tank, with 100-gallon and 120-gallon options being the most common. To determine the right capacity, consider your typical haul distance, fuel efficiency (usually 5-7 MPG), and weight restrictions. Many drivers opt for dual 120-gallon tanks for long-haul applications, while regional drivers often choose 100-gallon tanks to save weight. Check your door jamb sticker for factory tank specifications to ensure proper fitment.

Will aftermarket fuel tanks fit my specific T800 model year, and what mounting modifications are required?

Most aftermarket fuel tanks are designed to fit T800 models from 1987-2016, but mounting brackets and strap configurations vary by year. Pre-2007 models typically use 3-point mounting systems, while 2007-2016 models often require 4-point systems. Always verify your frame rail spacing (typically 34" or 34.5") and existing bracket hole patterns before ordering. Some 2010+ models may require adapter brackets due to emissions equipment placement. Professional installation is recommended as improper mounting can lead to stress cracks.

What's the difference between aluminum and steel fuel tanks, and which material lasts longer?

Aluminum tanks are 65% lighter than steel (saving approximately 100-150 lbs per tank) and resist corrosion better, typically lasting 15-20 years with proper maintenance. Steel tanks cost 30-40% less upfront but may rust internally within 8-10 years, especially in regions using road salt. Aluminum tanks are preferred for weight-sensitive applications and better fuel economy, while steel tanks offer better impact resistance for severe-duty applications like logging or construction.

What are the common installation challenges when replacing T800 fuel tanks?

The most common challenges include: relocating DEF tanks on 2011+ models, rerouting fuel lines around aftertreatment systems, and dealing with corroded mounting hardware. Plan 4-6 hours for installation per tank. You'll need new fuel line fittings (typically 1/2" or 5/8" NPT), sending unit gaskets, and potentially new mounting straps. Watch for interference with battery boxes, exhaust systems, and step tanks. Many installers report difficulty accessing upper mounting bolts on sleeper models - a 24" extension and swivel socket are essential.

What fuel tank shapes work best for different T800 applications?

D-shaped tanks maximize capacity while maintaining ground clearance, ideal for highway applications. Cylindrical tanks offer better structural integrity for off-road use but hold 10-15% less fuel. Step tanks (25-50 gallons) are popular for day cabs needing extra ground clearance. For dump truck and mixer applications, choose rear-fill tanks to avoid interference with hydraulic components. Polished aluminum and chrome options are available, but most drivers choose mill finish for durability and cost savings - appearance coatings typically add $200-400 per tank.