PROCEDURE: Fixing broken bolts on the fuel tank where the fuel sending unit attaches:
Section 1 of 4:
Quick Summary:
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A: Drill a small pilot hole as straight up and down as possible.
B: Drill a larger hole, the necessary size for the new bolt.
C: Thread the hole from the bottom up.
D: Install the new bolt with rubber washers
Detailed Explanation:
The Problem: You need to remove the sending unit from your fuel tank and you break a bolt while trying to get it off.
In my case, I soaked all eight bolts with penetrating liquid for five days before I tried to loosen them. Six came loose, but two broke loose from the tank at the rivet/weld underneath. The nut and bolt just spun when I turned it. So to get my sending unit off, I needed to break the bolts intentionally…and then repair them afterward.
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I had two bolts that needed to be fixed. Note the rivet/weld underneath:
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