Western Star Constellation Truck Fuel Tanks

Frequently Asked Questions About Western Star Constellation Truck Fuel Tanks

What size fuel tank options are available for Western Star Constellation models?

Western Star Constellation trucks typically accommodate fuel tanks ranging from 50 to 150 gallons per side. The most common configurations include 100-gallon and 120-gallon aluminum tanks, with dual tank setups offering 200 to 300 gallons total capacity. Tank diameter options include 23-inch and 25-inch round tanks, with lengths varying based on your truck's wheelbase and frame rail spacing. Always verify your specific model year's frame dimensions before ordering.

Are these fuel tanks compatible with 2005-2015 Western Star Constellation models?

Most aftermarket fuel tanks are designed to fit Western Star Constellation models from 2002-2021, but mounting brackets and strap configurations can vary significantly between model years. Pre-2008 models often use different mounting hardware than 2008-2015 versions. Critical compatibility factors include your truck's wheelbase, frame rail width (typically 34.5 inches), and whether you have a set-forward or set-back front axle. We recommend checking your VIN-specific specifications or contacting us with your truck details for exact fitment confirmation.

What's the difference between aluminum and steel fuel tanks for my Constellation?

Aluminum tanks are approximately 50% lighter than steel equivalents, reducing overall vehicle weight by 100-150 pounds for a dual tank setup. They resist corrosion better and typically last 15-20 years versus 8-12 years for steel tanks. However, aluminum tanks cost 30-40% more upfront and require special mounting hardware to prevent galvanic corrosion. Steel tanks offer better impact resistance and are easier to repair if damaged, making them popular for severe-duty applications.

Can I install these fuel tanks myself or do I need professional installation?

While experienced mechanics can complete the installation in 4-6 hours, we recommend professional installation due to DOT compliance requirements. The process involves disconnecting fuel lines, removing existing tanks, installing new mounting brackets (ensuring proper 1/2-inch ground clearance), connecting fuel sending units, and properly routing vent lines. You'll need specialized tools including strap tensioning equipment and potentially fuel line flaring tools. Improper installation can result in fuel leaks, tank damage, or DOT violations.

Do these replacement tanks include sending units and mounting hardware?

Most fuel tanks are sold without sending units, mounting straps, or brackets unless specifically noted as complete kits. Sending units typically cost an additional $75-150 per tank and must match your fuel gauge type (240-33 ohm is standard). Mounting strap kits run $50-100 per tank. Some tanks include NPT fittings for fuel lines and vents, but you'll usually need to purchase fuel line fittings, vent caps, and anti-siphon devices separately. Always verify what's included before ordering to avoid installation delays.