Kenworth Fuel Tanks

Frequently Asked Questions About Kenworth Fuel Tanks

What fuel tank sizes are available for my Kenworth truck model?

Kenworth fuel tanks typically range from 50 to 150 gallons, with the most common sizes being 75, 100, 120, and 150 gallons. For W900 models, dual 120-gallon or 150-gallon setups are popular, while T680 and T880 models often use 100 or 120-gallon configurations. Tank diameter varies between 23, 25, and 26 inches depending on capacity. Always verify your frame rail spacing and wheelbase before ordering, as these factors determine maximum tank size compatibility.

Will aftermarket fuel tanks fit my specific Kenworth year and model?

Most aftermarket fuel tanks are designed to fit multiple Kenworth models from 1985 to present, including W900, T800, T880, T680, and T660 series. However, mounting strap spacing and step configurations vary by year. Pre-2007 models typically use 14-inch strap spacing, while 2008 and newer models use 16-inch spacing. EPA-compliant models (2011+) may require additional venting modifications. Check your existing tank's mounting dimensions or contact us with your OEM for exact fitment verification.

What is the difference between aluminum and steel fuel tanks?

Aluminum tanks are 65% lighter than steel equivalents, improving fuel economy and payload capacity. They resist corrosion better and typically last 15-20 years with proper maintenance. Steel tanks cost 30-40% less upfront but are prone to rust, especially in salt-belt states, and usually need replacement after 8-10 years. Aluminum tanks feature welded construction while steel tanks use crimped seams. Most owner-operators prefer aluminum for long-term value, while fleet operators sometimes choose steel for lower initial investment.

Can I install a fuel tank myself or do I need professional installation?

While experienced mechanics can install fuel tanks themselves, professional installation is recommended due to DOT regulations and safety requirements. Installation typically takes 3-4 hours per tank and requires proper lifting equipment, torque specifications for mounting straps (45-55 ft-lbs), and correct fuel line routing. You must also ensure proper grounding, install new fuel sending units if needed, and verify crossover line compatibility on dual tank setups. Many states require certified installation for warranty and inspection purposes.

What finish options are available and which holds up best?

Fuel tanks come in three main finishes: polished aluminum, brushed aluminum, and powder-coated steel. Polished aluminum provides the classic chrome-like appearance but requires monthly polishing to maintain shine. Brushed aluminum offers a maintenance-free satin finish that hides minor scratches and water spots. For harsh climates and minimal maintenance, brushed aluminum is most practical, while polished aluminum remains popular for show trucks and owner-operators who prioritize appearance.