Updated at: 04-08-2022 - By: Lucas

For those of us who have been driving cars for a while, we know that failures are inevitable and that things break when we least expect them. Even if you’re simply thinking about getting a car, it’s smart to be prepared for potential difficulties and how to avoid them.

Despite the fact that broken gas tanks aren’t a typical occurrence, you don’t want to have to deal with them any time soon. In the good news, fixing a leaking gas tank will not set you back an arm and an eye.

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

Cracked Gas Cap

Sharp objects

Cracks in the gas tank can be caused by a sharp object, such as a stone, being knocked into it by the wheels, which can cause the tank to shatter. As soon as you notice cracks, even if they aren’t particularly large, it is critical to take action before the problem worsens.


Corrosion might have a greater impact on your gas tank than you might anticipate. Before the leak gets out of hand, you need to know where it is coming from.

How can you repair a cracked fuel tank?

Cracked Gas Cap-2

The first and most obvious alternative is to have a workshop or your mechanic do a car overhaul, especially if you do not have in-depth knowledge of how to repair this problem.

If the damage is too extensive and irreparable, they may decide to replace the tank entirely. However, you should get the advice of an expert in the field before making any personal interventions.

Many times, you may be able to fix a problem yourself and save money by not calling a repair. The good news is that you can save a lot of money by tackling the problem on your own, but you must first fully comprehend the situation in order to intervene appropriately and efficiently.

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

As a first stage, lift the vehicle so that a goat may easily be inserted under it for support. The next step is to ensure that the car is on a surface that allows you to begin the intervention without difficulty, going under the vehicle.

3. Check the exact location of the leak

In many circumstances, the tank cracks are virtually minute, therefore you must be extremely attentive to discover the specific problem, which is the crack where fuel leaks.

4. Smooth the area around the leak

A few inches on each side of the crack should be smoothed using sandpaper.

5. Clean the area

Clean a clean towel with which to wipe down the area. Make use of technical or degreasing alcohol if necessary to ensure that all contaminants are removed.

6. Epoxy repair kit

If this is your first time using this kit, you’ll need the instruction manual. You must swiftly combine the two tubes’ components and apply this mixture before it hardens or dries. Fortunately, the directions are frequently included on the packaging.

7. Give a form to the compound

In order to construct a cone, you’ll need to remove a piece of around 3 centimeters from the mixture and shape it into an oval.

8. Apply the combination

Insert the cone-shaped combo into the gas tank’s hole now. The combination must be used until the crack is completely closed, and then the balance of the compound can be put to the sanded surface. A few sips of water can go a long way in making things easier.

9. Try your new fuel tank

To ensure that the repair is complete, you need to make sure that the intervention worked. As you normally would, fill up the gas tank and look for signs of fuel leakage. To ensure that your tank is reliable, follow all of the instructions in this article.

Remember, however, that driving a car with a crack in the tank is never a good or suggested alternative. In the end, things can get a little crazy, and you might even get shot. As a result, avoid wasting time by calling a mechanic or attempting to fix the problem yourself. Get it figured out before you get behind the wheel so that you can be sure to get at your destination safely