Western Star 5700XE Truck Fuel Tanks

Frequently Asked Questions About Western Star 5700XE Truck Fuel Tanks

What size fuel tanks are available for the Western Star 5700XE, and which configuration provides the best range?

The Western Star 5700XE typically accommodates fuel tanks ranging from 80 to 150 gallons per side. Most drivers prefer the dual 120-gallon aluminum tank setup (240 gallons total) for optimal balance between weight savings and range. The 150-gallon options are available but add considerable weight. Your specific frame rail configuration and wheelbase will determine the maximum tank size that fits properly without interfering with other components.

Will aftermarket fuel tanks void my Western Star warranty, and what brands are recommended?

Installing aftermarket fuel tanks generally won't void your entire vehicle warranty, but it may affect warranty coverage for fuel system components directly connected to the tanks. We recommend sticking with OEM-spec tanks from trusted manufacturers like Minimizer, Jones Performance, or A&A Manufacturing. These brands design their tanks to match Western Star specifications and use the same mounting points and connections as factory tanks.

What's involved in installing replacement fuel tanks on a 5700XE, and can I do it myself?

Fuel tank replacement requires draining existing fuel, disconnecting fuel lines, sender units, and mounting straps, then reversing the process with new tanks. While mechanically inclined owners can handle this job, you'll need proper lifting equipment, fuel transfer pumps, and safety gear. Most installations take 4-6 hours per tank. Common challenges include aligning mounting brackets on older trucks and ensuring proper clearance for DEF tanks on 2011+ models.

Should I choose aluminum or steel fuel tanks, and what's the real-world difference in longevity?

Aluminum tanks are 40-50% lighter than steel equivalents and won't rust, making them ideal for weight-conscious operations and coastal regions. However, they're more expensive and can develop stress cracks around mounting points after 7-10 years of heavy use. Steel tanks cost less upfront and handle impacts better but require vigilant maintenance to prevent rust, especially around strap contact points. In moderate climates with proper care, steel tanks typically last 10-15 years.

My 5700XE has dual tanks but uneven fuel draw - is this normal, and what tank modifications might help?

Uneven fuel draw between dual tanks is a common issue on 5700XE trucks, especially 2015-2018 models. This usually stems from fuel return line routing or crossover valve problems rather than the tanks themselves. Before replacing tanks, check that both fuel pickups are at the same height and that your crossover lines aren't restricted. Some drivers install aftermarket equalizer valves or electronic tank switching systems to ensure balanced fuel usage.