Sylvie Willis
A broken fuel tank strap bolt can be a challenging issue to resolve, but it's not impossible. The first step is to assess the damage and determine if the bolt can be removed. If the bolt is accessible, one possible solution is to grind away the broken stud and weld a new bolt in its place. This method has been suggested by several individuals facing similar issues. It is important to note that this solution may not be suitable for all situations, and seeking professional advice or consulting a mechanic is recommended. As a temporary solution, one suggestion is to use a ratchet strap to secure the fuel tank, but this is not a permanent fix and should only be used until a more durable solution is implemented.
How to repair a broken fuel tank strap bolt
| Characteristics | Values |
|---|---|
| Short-term repair | Put a ratchet strap in its place and tighten it down |
| Permanent repair | Grind away the remainder of the stud. Weld a same-sized bolt in its place |
| Alternative repair | Install two button-head bolts with washers and bolt it up |
| Tools | Vise grips, jack, washers |
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What You'll Learn
Short-term repair: Ratchet strap as a temporary fix
A broken fuel tank strap bolt can be temporarily fixed by using a ratchet strap. This is not a permanent solution, but it will work as a short-term repair.
First, purchase a ratchet strap. These are readily available at hardware stores and can also be found at Walmart for a low price. Next, hook the ratchet strap in place of the original strap. You can hook the ends of the ratchet strap near where the original fuel tank strap was hooked. Ensure that the ratchet strap is tightened down.
This temporary fix will allow you to drive your vehicle without issue until you can replace the fuel tank strap bolt. It is important to note that, while this solution is functional, it is not a long-term fix, and the fuel tank strap bolt should be replaced as soon as possible.
Some people have reported using this temporary fix for extended periods, but it is not recommended as a permanent solution. It is always best to consult a professional mechanic for a permanent repair to ensure the safety and proper functioning of your vehicle.
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Long-term repair: Replace the bolt
If you are looking for a long-term solution to repair a broken fuel tank strap bolt, you will need to replace the bolt. This process can be complex and may require specialized tools, so it is recommended that you have some mechanical knowledge or experience before attempting it. Here is a step-by-step guide to help you through the process:
First, you will need to gather the necessary tools and materials. These include a new fuel tank strap with bolts, a jack, and some form of lubricant or penetrant. Soaking the u-nuts with penetrant can help ease the process. It is also recommended to have a wrench or ratchet strap on hand to secure the fuel tank in place.
Next, safely raise the vehicle using a jack to access the fuel tank and strap. Ensure the vehicle is securely lifted and supported to prevent any accidents or injuries. Once you have accessed the fuel tank, you may need to remove it to reach the broken bolt easily. This step may vary depending on your vehicle's specific make and model.
With the fuel tank moved or removed, you can now focus on the broken bolt. If the bolt is rusted or seized, you may need to cut it using a suitable tool, such as an air hammer and chisel. Be cautious when cutting, as fuel tanks can be explosive. Alternatively, you can attempt to drill out the bolt, but again, be cautious to avoid any sparks that could cause an explosion.
Once the broken bolt has been removed, you can now replace it with a new one. Ensure the new bolt is compatible with your vehicle's fuel tank strap and tighten it securely. Reattach the fuel tank if you had to remove it earlier.
Finally, lower the vehicle and ensure the fuel tank strap is secure and functioning correctly. Test the vehicle to ensure the repair was successful.
While this guide provides a general framework for replacing a broken fuel tank strap bolt, specific steps may vary depending on your vehicle's unique characteristics. Always refer to your vehicle's repair manual or seek advice from a qualified mechanic if you are unsure about any steps or procedures.
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Grind and weld a bolt
To repair a broken fuel tank strap bolt, one method is to grind and weld a bolt. Here is a step-by-step guide on how to do this:
Prepare your workspace and safety gear:
Ensure you have a clean and well-lit workspace. Put on safety goggles to protect your eyes from sparks and metal debris, ear protection to safeguard your hearing, and heavy-duty gloves to shield your hands. It is also recommended to wear long sleeves and pants for added protection.
Measure and mark the bolt:
Using a measuring tape, determine the desired length of the bolt. Clearly mark the cutting point on the bolt using a marker or chalk. Double-check the measurement to ensure accuracy.
Set up your angle grinder:
Select the appropriate cutting disc for metal and follow the manufacturer's instructions for proper installation. Ensure the grinder is unplugged during the disc change and double-check its tightness to prevent accidents.
Position and cut the bolt:
Hold the angle grinder with both hands, placing your dominant hand on the main handle and your non-dominant hand on the auxiliary handle. Position the cutting disc at a slight angle, approximately 30 degrees, to the bolt. Gradually lower the disc onto the bolt while applying slight pressure. Move the grinder smoothly along the marked cutting line, maintaining a consistent depth. Avoid pausing mid-cut to prevent overheating. If the bolt is thick, you may need to make multiple passes, adjusting the angle of the grinder after each pass.
Post-cutting steps:
Once you've cut through the bolt, release the pressure, turn off the grinder, and allow the cutting disc to stop completely. Inspect the cut to ensure it is clean and free of sharp edges. Clean up the work area by removing any metal shavings or debris, disposing of them properly to avoid hazards.
Grinding and welding:
Before welding, it is essential to remove any coatings, such as zinc, from the bolt and the nut to avoid contamination and ensure a strong weld. Use a wire brush or a grinder to clean the surfaces. If using a grinder, wear a respirator to protect yourself from the grinding debris. After grinding, you can proceed with the welding process, ensuring proper ventilation in your workspace.
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Using vice grips to remove the bolt
To repair a broken fuel tank strap bolt, you may need to use vice grips to remove the bolt if it is stuck. This is a common issue, especially with GM truck tank strap bolts, where the bolt can sit and spin due to a broken or rusted cage nut.
First, try to pry the strap down and apply some force to it. This may help loosen the bolt's grip on the strap, and it might come out along with the strap. If not, the next step is to use the vice grips.
Before using the vice grips, you may want to try some other methods to loosen the bolt. For example, you could try using a breaker bar, liquid wrench, or a heavy-duty impact wrench to try and loosen the bolt. If these methods do not work, then you can proceed with the vice grips.
Take your vice grips and clamp them tightly onto the bolt head. This will allow you to get a good grip on the bolt and prevent it from spinning when you try to remove it. Make sure the vice grips are securely attached to the bolt before applying force.
Once the vice grips are securely clamped onto the bolt head, you can try to remove the bolt by twisting and pulling it out. This may require significant force, especially if the bolt is rusted or damaged. It may help to wiggle the bolt back and forth to loosen it before trying to pull it out.
If the bolt is still difficult to remove, you may need to cut the bolt head off. This can be done with a drill or an air hammer and chisel. Be extremely careful when using power tools around fuel tanks, as sparks can be dangerous. Once the bolt head is removed, you can pound out the rest of the bolt.
Finally, with the bolt removed, you can replace the fuel tank strap and install a new bolt. Make sure to tighten the new bolt securely, but be careful not to over-tighten it, as this could cause issues in the future.
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Replace the fuel tank strap
If you need to replace a fuel tank strap, it is advisable to first remove the old fuel tank. Then, you can swap out the straps and put the new tank in.
To remove the old strap, you will need to swing the whole strap to one side of the car to slip the pin out of the pocket. Each bolt has one strap with one side bolted in and the other a rod that sits in this pocket. You may need to remove the tank to swing the strap enough to slide it out of the brackets.
When installing the new strap, the process is essentially the reverse. You will need to rotate the strap about 90 degrees, slot that into the opening, then rotate the strap to the proper orientation. The new straps should already have the pins in them, and they are not designed to come out. You may need to bend the straps by hand to get them to conform to the fuel tank profile.
As a temporary fix, some suggest using a ratchet strap to tighten the tank down. However, this is not a permanent solution and you should replace the straps as soon as possible.
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Frequently asked questions
If the bolt is broken, you will need to replace it with a new bolt. Grind away the remainder of the broken bolt, and weld a new bolt of the same size in its place.
To remove a broken bolt, you can try prying the strap down and hitting it with an impact at the same time. You can also try using vise grips to get the bolt out.
As a temporary solution, you can use a ratchet strap to secure the fuel tank. This is not a permanent solution, and you should look to replace the bolt as soon as possible.
You should replace the fuel tank strap if it is rusted. You can purchase new gas tank straps and bolts from a hardware store or online.
