Frequently Asked Questions About Kenworth W900A Diesel Fuel Tanks

What size fuel tanks are available for the Kenworth W900A, and how do I choose the right capacity?

Kenworth W900A fuel tanks typically range from 50 to 150 gallons per tank. Most drivers opt for dual 100-gallon or 120-gallon setups for long-haul applications. To choose the right capacity, consider your typical route distances, fuel economy (usually 5-7 MPG), and weight restrictions. Remember that diesel weighs approximately 7 pounds per gallon, so larger tanks add significant weight. For regional routes under 500 miles, 50-75 gallon tanks are often sufficient, while cross-country haulers benefit from 100+ gallon configurations.

Will these fuel tanks fit my specific year W900A, and what about mounting hardware compatibility?

Our fuel tanks are designed to fit Kenworth W900A models from 1961 through 1990. However, mounting bracket configurations changed in 1973 and again in 1982. Pre-1973 models use a 3-strap system, 1973-1981 models use a modified 3-strap with different spacing, and 1982-1990 models typically use a 2-strap system with reinforced brackets. Always verify your truck's VIN and existing mounting system before ordering. We recommend ordering matching mounting straps and brackets with your tank to ensure proper fitment.

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

We offer both aluminum and steel fuel tanks. Aluminum tanks are 65% lighter than steel equivalents, resist corrosion better, and are ideal for weight-conscious operations. They typically last 15-20 years with proper maintenance. Steel tanks are more affordable upfront, more resistant to impact damage, and easier to repair if punctured. However, they require regular inspection for rust, especially in salt-belt states. Most owner-operators prefer aluminum for the weight savings, while fleet operators often choose steel for the lower initial cost.

How difficult is the installation process, and can I do it myself?

Installation typically takes 3-4 hours per tank for experienced mechanics. The process involves draining existing fuel, removing old tanks, transferring fuel sending units and pickup tubes, mounting new tanks with proper alignment, and reconnecting fuel lines. Critical considerations include ensuring proper ground clearance (minimum 12 inches), correct strap tension to prevent movement, and proper venting to avoid vacuum issues. While DIY installation is possible with basic tools, we recommend professional installation to ensure DOT compliance and prevent fuel system problems.

What's the difference between round and D-shaped tanks, and which style works best?

Round tanks are the traditional choice, offering maximum capacity for their size and even weight distribution. They're easier to clean internally and typically cost less. D-shaped (or rectangular) tanks mount flush against the frame rails, providing better ground clearance and a cleaner appearance. They're preferred for show trucks or applications requiring maximum clearance. D-tanks typically hold 10-15% less fuel than equivalent-length round tanks. Most W900A operators choose round tanks for practicality, but D-tanks are popular for custom builds or trucks with aftermarket side fairings.