Western Star 4700 Truck Fuel Tanks

Frequently Asked Questions About Western Star 4700 Truck Fuel Tanks

What fuel tank sizes are available for my Western Star 4700, and how do I know which one fits?

Western Star 4700 trucks typically accommodate fuel tanks ranging from 50 to 150 gallons, with 100 and 120-gallon tanks being the most common. The correct size depends on your truck's wheelbase and frame rail configuration. Tanks are measured in diameter (usually 23" or 25") and length. To ensure proper fit, check your frame rail spacing and measure from the back of the cab to the rear suspension components. Most 4700 models from 2011-2024 use standard 23" diameter tanks, but always verify your specific model year and configuration before ordering.

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

Both aluminum and steel fuel tanks are available for the Western Star 4700. Aluminum tanks are lighter (reducing overall vehicle weight by 50-70 pounds compared to steel), resist corrosion better, and are ideal for weight-sensitive applications or coastal regions. Steel tanks are more affordable, highly durable against impacts, and easier to repair if damaged. For most over-the-road applications, aluminum is preferred, while steel tanks work well for construction or heavy-duty vocational use where impact resistance is crucial.

Can I install a replacement fuel tank myself, or do I need special tools and expertise?

While fuel tank installation is possible for experienced mechanics, it requires specific safety precautions and tools. You'll need tank straps, mounting brackets, proper lifting equipment, and fuel line disconnect tools. The process involves draining the existing tank, disconnecting fuel lines and sending unit wiring, and ensuring proper grounding. Most installations take 3-4 hours. Due to safety concerns with fuel handling and the need to properly torque mounting hardware to manufacturer specifications, many truck owners prefer professional installation, which typically costs $200-400 in labor.

What's the difference between round and D-shaped fuel tanks for the Western Star 4700?

Round tanks are the standard option, offering maximum fuel capacity and easier mounting with simple strap systems. D-shaped (or rectangular) tanks mount flush against the frame rail, providing better ground clearance and a cleaner appearance. D-tanks are ideal for vocational trucks operating off-road or in tight spaces but typically hold 10-15% less fuel than round tanks of similar dimensions. Round tanks work best for highway applications where maximum range is priority, while D-tanks suit construction and delivery applications.

Do aftermarket fuel tanks come with sending units, or do I need to transfer mine?

Most aftermarket fuel tanks for the Western Star 4700 are sold without sending units, requiring you to transfer your existing unit or purchase one separately. When transferring, inspect the sending unit gasket and replace if worn (typically $15-25). New sending units designed for Western Star applications cost between $75-150. Ensure compatibility by checking if your truck uses a 5-bolt or 6-bolt sending unit pattern, as this varies by model year. Some premium tank packages include new sending units, but always verify what's included before ordering.