Replacing Fuel Tank Straps: A Step-By-Step Guide For Beginners

Fuel tank straps are an essential component in vehicle design, responsible for the secure mounting of the fuel tank to the vehicle's frame or body. Replacing a fuel tank strap is a relatively simple task that can be done with a basic set of hand tools and a jack. The process involves removing the fuel tank shield retaining strap, taking off the plastic fuel tank shield, using a jack to support the tank, removing the pin from one side of the strap, and then unbolting the remaining side. However, it is important to note that working with fuel tanks can be dangerous, and it is recommended to have some mechanical experience before attempting this repair.

Identify if the fuel tank straps are broken or corroded

Fuel tank straps are an essential component of a vehicle's fuel tank, and their failure can lead to hazardous situations. Here are some detailed instructions to identify if the fuel tank straps are broken or corroded:

Firstly, it is important to understand the function and location of fuel tank straps. These straps are usually made of metal and are responsible for securely holding the fuel tank in place, ensuring it doesn't move or shift while the vehicle is in motion. They are typically located underneath the vehicle, close to the fuel tank and the frame rail.

To identify if the fuel tank straps are broken or corroded, follow these steps:

• Park the vehicle on a level surface and engage the parking brake: This ensures the vehicle remains stationary during your inspection.
• Place a jack and jack stands: Position the jack and jack stands at the manufacturer's recommended lift points to safely raise the vehicle. This will provide you with access to the undercarriage and fuel tank assembly.
• Locate the fuel tank and its straps: Refer to your vehicle's service manual or an online forum specific to your car model to identify the exact location of the fuel tank and its straps.
• Visually inspect the fuel tank straps: Look for any signs of damage, deformation, or corrosion on the straps. Broken straps may have cracks, fractures, or missing sections. Corrosion will appear as rust or a build-up of oxide on the surface of the straps. Pay close attention to areas where the straps attach to the fuel tank and the vehicle's frame.
• Check for loose or detached straps: If a strap appears loose or detached at any point, it may indicate a failure or impending failure.
• Inspect for fuel leaks: Leaking fuel can also be an indicator of strap failure. If you notice any fuel stains, dripping fuel, or strong fuel odours, it may suggest that the tank is not securely held in place.
• Examine the condition of the fuel tank: If the fuel tank appears to be resting at an unusual angle or seems lower than normal, it could be a sign that the straps are compromised.
• Feel the straps for weakness: Carefully touch the straps to feel for any areas that seem weak, brittle, or excessively flexible. Corroded or damaged straps may exhibit these characteristics.
• Compare with new straps: If possible, compare the straps on your vehicle with new, undamaged straps designed for your specific car model. This can help you identify any deviations from the original condition.
• Check for vehicle-specific issues: Some vehicle models are known to have common issues with fuel tank straps. For example, certain Toyota Tundras experienced problems with spare tires detaching due to excessive rust. Knowing such issues can help you identify potential problems with the straps.

Remember, if you identify any issues with the fuel tank straps, it is crucial to address them immediately. Do not drive the vehicle if the straps are severely corroded, broken, or detached, as it can lead to a hazardous situation. Always prioritise your safety when working on or around a vehicle, especially when dealing with flammable substances like fuel.

Use a jack to support the tank

To replace a fuel tank strap, you will need to use a jack to support the tank. Here is a detailed, step-by-step guide on how to do this:

Firstly, before you begin, ensure that you have carefully removed any previous methods of supporting the tank, such as a ratchet strap. It is important to do this when the fuel level is low, as a full tank will be heavier and more difficult to work with.

Next, use a jack to support and lift the tank. Push the tank back up slightly to make room for the next steps.

Once the tank is secure, you can begin to remove the fuel tank strap. Start by removing the pin from one side of the strap, located near the centre of the vehicle by the driveshaft. Then, unbolt the remaining side of the strap. This bolt may be challenging to remove due to built-up dirt and mud, so it is recommended to spray it with WD40 or a similar product to make the process easier.

At this point, you have successfully removed the old fuel tank strap. Now, you can install the new strap by following the previous steps in reverse. First, bolt one side of the new strap into place, ensuring that the pin is securely seated in the bracket. Then, jack the tank up slightly higher to fit the new strap into place, and bolt the other side.

Finally, once the new strap is securely in place, you can relocate the jack as needed to continue supporting the tank. Remember to double-check that the tank is securely fastened before lowering it and continuing with any other necessary repairs.

By following these steps, you can safely and effectively use a jack to support the fuel tank and replace the fuel tank strap.

Remove the pin from one side of the strap

Removing the pin from one side of the strap can be a challenging task, especially if the pin is rusted or stuck. Here is a detailed guide to help you through the process:

First, it is important to understand the function of fuel tank straps. Fuel tank straps are essential components that securely mount the fuel tank to the vehicle's frame or body. They ensure the safe and reliable transportation of fuel during the operation of the vehicle. When replacing the fuel tank straps, it is crucial to have a clear understanding of the strap's design and the specific steps involved.

Now, to remove the pin from one side of the strap, start by identifying the type of pin and strap mechanism your vehicle has. In some cases, the pin may act as a hinge, and you can simply pull down the strap without removing the pin. However, in other cases, the pin may be inserted through the strap and secured in a bracket or tab. If the pin is rusted or stuck, it may require more effort to remove.

Before attempting to remove the pin, make sure you have the necessary tools and safety equipment. This may include items such as wrenches, a jack to support the fuel tank, and safety gear such as gloves and eye protection. It is also recommended to place the vehicle on a lift or jack stands to provide better access and ensure stability.

To remove the pin, you may need to tilt or swing the fuel tank strap to one side. This will allow you to access the pin and bracket assembly. Use a wrench or a similar tool to grip the pin firmly. If the pin is rusted, you may need to use a penetrating lubricant to help loosen it. Try twisting or gently tapping the pin with a hammer to dislodge it from the bracket. Be careful not to use excessive force, as you don't want to damage the surrounding components.

In some cases, if the pin is severely rusted or damaged, you may need to cut it off using a cut-off wheel or a similar tool. This should be done with caution, ensuring that you don't damage the strap or any other parts of the vehicle. Once the pin is removed, you can install a new pin or proceed with replacing the fuel tank strap, following the manufacturer's instructions or seeking guidance from a trusted mechanic.

Remember, working on fuel tank straps can be dangerous, especially if you are not familiar with the process. Always prioritize your safety and the safety of those around you. If you are uncomfortable with any part of the process, don't hesitate to seek professional assistance.

Unbolt the remaining side of the strap

To unbolt the remaining side of the strap, you will need to spray the bolt with WD40 or a similar product. This is because the bolt sits in a bracket that is usually full of water and mud, so it can be challenging to remove. You can spray it horizontally inside the bracket to cover the threads inside the frame.

Once you have sprayed the bolt, you will need to use a wrench to unbolt it. The size of the wrench you need will depend on the make and model of your vehicle. For example, a 1/2 or 9/16 inch wrench may be required for a Ford F150. It is important to use the correct size wrench to avoid damaging the bolt or the bracket.

If the bolt is very difficult to remove, you may need to use a plasma cutter to cut the old strap off. However, this should be avoided if possible, as it can create sparks that could be dangerous around the fuel tank.

Once the remaining side of the strap has been unbolted, you can install the new strap by following the same procedure in reverse. You may need to jack the tank up to fit the new strap in place.

Repeat for the other strap if necessary

Now that you have successfully replaced one of the straps, you can repeat the process for the other strap if necessary. This will ensure that your fuel tank is securely mounted to the vehicle's frame or body, providing safe and reliable fuel transportation during operation.

To begin, make sure you have the necessary tools and a new strap. You will need a jack to support the full tank, and a wrench in the appropriate size. It is recommended to use a 1/2 or 9/16-inch wrench, but you may need a metric wrench if the nut is metric.

First, support the fuel tank with a jack and remove the old strap. You may need to spray the bolt with WD-40 or a similar product to make it easier to remove if it has been sitting in water or mud. Remove the pin from one side of the strap and then unbolt the remaining side. Take care not to lift the vehicle by the tank and do not attempt to cut the strap with a plasma cutter, as this can create sparks and pose a safety hazard.

Once the old strap is removed, install the new strap by following the same steps in reverse. Make sure to jack up the tank as needed to fit the new strap properly. Check that the tank is securely supported throughout the process.

Finally, repeat the entire procedure for the other strap if both need to be replaced. This will ensure that your fuel tank is securely held in place and reduce the risk of early tank failure due to corrosion.

Frequently asked questions