Section 1 of 4:

Quick Summary:





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.


I had two bolts that needed to be fixed. Note the rivet/weld underneath: