How to repair a cracked fuel tank

If you have already owned a car for a while, you know that failures are something you just need to get used to and things crack and break when you least expect it. If you are just considering buying a car, it is better to know from the beginning the possible problems that may arise and how to prevent them as best.

A broken gas tank is not a very popular or common problem because the lifespan of the car gas tank is quite long, but you certainly will not want to deal with it. The good news, however, is that it won’t cost you a fortune to repair a broken or cracked gas tank.

Main causes that can lead to fuel leakage from a broken gas tank?

Sharp objects

One of the most common causes that can lead to cracking the gas tank is that it can come in contact with a sharp object, for example, stones, which may have been bounced off from the wheels. Even if cracks are not, in the early stage, extremely large, it is imperative to intervene as soon as possible, before the problem worsens.


Depending on the region, corrosion can affect your gas tank more than you would expect. You have to pay attention to the exact place where the leak comes from before it gets worse.

How can you repair a cracked fuel tank?

The first and most obvious option, especially if you do not have in-depth knowledge about repairing this problem, is to call a workshop or your mechanic to do a car overhaul.

Maybe they will opt to completely replace the tank if the damages suffered are too big and irreparable. However, before you intervene personally, it is advisable to consult the opinion of a specialist in the field.

But in many cases, you may have the necessary knowledge and do not want to throw a lot of money to call a mechanic. The good news is that if you want to move forward in solving the problem on your own, you will save a lot of money, but for your safety, you must understand exactly how things are going to be able to intervene effectively and correctly.

1. What tools will you need to repair a cracked gas tank?

  • A clean towel or cloth;
  • The mask;
  • Protective eyewear;
  • A jack;
  • Sandpaper;
  • Epoxy repair kit, fuel tank repair kit (you’ll find more variants);
  • Degreaser or technical alcohol;
  • Gloves for kitchen or vinyl;

2. Raise the car on the jack

The first step you will need to do is to raise the car enough so that you can easily insert a goat under it, to lean on. Then you have to make sure that the car rests on something that allows you to start the intervention without problems, going under the car.

3. Check the exact location of the leak

Remember that in many cases the cracks in the tank are almost microscopic, so you have to be very careful to locate the exact problem, the crack where the fuel leaks.

4. Smooth the area around the leak

Using the sandpaper, try to smooth the area around the crack, about a few inches on each side.

5. Clean the area

Now it is time to use a clean towel with which you can clean the area. Also, do not shy away from using technical or degreasing alcohol to be sure you get rid of all the impurities.

6. Epoxy repair kit

To use this kit, especially if it is the first time, you will need the user manual. You must put together the components of the two tubes and apply them quickly before this combination hardens or dries. The good news is that the instructions will usually be found on the packaging.

7. Give a form to the compound

At this point, you will need to cut a piece of about 3 centimeters from the combination formed and form a kind of cone, with a wider base and a narrower tip.

8. Apply the combination

Now you will need to insert the cone-shaped combination into the crack in the gas tank. You must use the combination until the crack tightly closes, and the rest of the compound can be applied to the surface that you have already smoothed with the sandpaper. A little water can help make the process easier.

9. Try your new fuel tank

For the repair to be complete, you must check if the intervention was successful. Try to fuel the gas tank, as you would normally, and then pay attention to possible fuel leaks. If you have followed the steps described above, you should have a new tank that you can rely on.

Keep in mind, however, that it is never a good or recommended option to drive a car with a crack in the tank. Problems can be very serious and you can even get a blast, eventually. Thus, whether you call a mechanic or try to solve the problem by yourself, never waste time. Better solve it early to drive safely!

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