Fuel Tank Repair Service Costs
Plastic Fuel Tank Repairs
Typical repair time: 2-3 hours
Average cost: $250-$375
Common repairs include crack welding, pin hole repairs, and fuel sender unit replacement. Price may vary based on tank accessibility and damage severity.
Metal Fuel Tank Repairs
Typical repair time: 3-4 hours
Average cost: $375-$500
Includes rust repair, welding of seams, and corrosion treatment. Additional costs may apply if extensive rust removal or tank cleaning is required.
Aluminum Fuel Tank Repairs
Typical repair time: 4-5 hours
Average cost: $500-$625
Specialized welding and repairs for marine and high-performance vehicles. Complex repairs may require additional time and materials.
*All prices are based on our standard labor rate of $125/hour. Additional parts and materials are not included in these estimates. Severe damage may require longer repair times. Please contact us for a detailed quote specific to your vehicle.
Emergency Fuel Tank Repairs
After-hours or emergency service may incur additional charges. Please call for current emergency service rates.
Fuel Tank Repair Procedures by Type
Plastic Fuel Tank Repair
Step 1:Thoroughly clean and dry the damaged area using appropriate solvents to remove fuel residue and debris.
Step 2:Sand the damaged area to create a rough surface for better adhesion.
Step 3:For small holes or cracks, apply specialized plastic fuel tank epoxy or repair kit.
Step 4:For larger damages, use plastic welding techniques with compatible materials.
Step 5:Allow repair to fully cure according to product specifications.
Step 6:Pressure test to ensure repair integrity.
Metal Fuel Tank Repair
Step 1:Drain and ventilate the tank completely.
Step 2:Clean the damaged area thoroughly using appropriate cleaning solutions.
Step 3:For small holes, apply metal epoxy or specialized fuel tank sealer.
Step 4:For larger damages, weld patches using appropriate welding techniques.
Step 5:Sand and smooth the repaired area.
Step 6:Apply protective coating to prevent future corrosion.
Step 7:Pressure test to ensure repair integrity.
Aluminum Fuel Tank Repair
Step 1:Empty and clean the tank thoroughly.
Step 2:Identify and mark all damaged areas.
Step 3:For minor damage, use specialized aluminum epoxy.
Step 4:For significant damage, TIG weld with compatible aluminum filler material.
Step 5:Clean and inspect welded areas.
Step 6:Apply protective coating if necessary.
Step 7:Conduct pressure testing to verify repair.
Important Note:All fuel tank repairs should be performed by qualified professionals in a properly ventilated area with appropriate safety equipment. Some repairs may require specialized certifications or approvals depending on the vehicle type and local regulations.
Understanding Different Types of Fuel Tanks
Main Fuel Tank
TheMain Fuel Tankis the primary storage container for your vehicle's fuel. Located typically underneath the vehicle, it's designed to safely store gasoline or diesel fuel and supply it to the engine. Most passenger vehicles have a main fuel tank capacity between 12-15 gallons for compact cars and up to 30+ gallons for larger SUVs and trucks.
Auxiliary Fuel Tank
AnAuxiliary Fuel Tankis a secondary fuel storage system that supplements your main tank. These tanks are often aftermarket additions that provide extended driving range without refueling. They're particularly popular among long-haul trucks, off-road vehicles, and work trucks that need additional fuel capacity for remote operations.
Saddle Tank
ASaddle Tankis a specially designed fuel tank that's shaped like a horse saddle, straddling another component of the vehicle (usually the driveshaft). This design maximizes fuel capacity while working around the vehicle's existing architecture. Commonly found in larger trucks and commercial vehicles, saddle tanks often come in pairs, one on each side of the vehicle.
Transfer Tank
ATransfer Tankis a portable fuel storage container typically mounted in the bed of a pickup truck. Unlike other fuel tanks, it's not connected to the vehicle's fuel system. Instead, it's used to transport fuel to other vehicles or equipment at job sites. These tanks often include pumping systems for easy fuel transfer.
Day Tank
ADay Tankis a smaller intermediate fuel tank that supplies fuel to engines or generators for daily operation. While not common in passenger vehicles, they're essential in industrial applications and backup power systems. Day tanks typically include fuel filtration systems and are automatically refilled from a main storage tank.
Reserve Tank
AReserve Tankis a small additional fuel tank that provides emergency fuel when the main tank runs empty. In modern vehicles, this is often integrated into the main tank design, giving you those extra few miles when your fuel gauge reads empty. This safety feature helps prevent complete fuel exhaustion on the road.
Note: All fuel tanks must meet strict safety standards and should only be installed by qualified professionals. Proper installation and maintenance are crucial for safe operation.
Fuel Tank Failure Symptoms: Warning Signs You Shouldn't Ignore
Signs of Fuel Tank Problems & Maintenance Schedules
Metal Fuel Tanks
Signs of Failure:
- Rust spots or corrosion on tank exterior
- Fuel leaks or drips under the vehicle
- Fuel gauge reading incorrectly
- Strong fuel smell
- Visible dents or damage
Service Schedule:
- Visual inspection every 12 months
- Internal cleaning every 5-7 years
- Replace after 15-20 years depending on conditions
Plastic (Polyethylene) Fuel Tanks
Signs of Failure:
- Cracks or splits in tank material
- Discoloration or chalking of tank surface
- Swelling or deformation
- Fuel seepage at seams
- Strong fuel odor
Service Schedule:
- Visual inspection annually
- Check for UV damage every 2 years
- Replace after 10-15 years
Composite Fuel Tanks
Signs of Failure:
- Delamination of layers
- Hairline cracks in outer layer
- Bubbling or blistering
- Fuel weeping through walls
- Impact damage
Service Schedule:
- Professional inspection every 6 months
- Pressure testing every 2-3 years
- Replace after 8-12 years depending on usage
Note: These are general guidelines. Actual service intervals may vary based on usage conditions, climate, and manufacturer recommendations. Always consult your vehicle's manual or a professional technician for specific maintenance schedules.
How It Works
- Get a quote online or set-up a time to have your vehicle looked at.
- Pick time slots that work for you, easily, online.
- We will confirm appointments and send reminders.
- Our mechanics bring everything that is needed to you.
- All you have to do is provided a safe area for the work to be performed.
What we need from you
- A safe place to work on your vehicle
- No working on the side of busy roads
- No working on unstable or steep surfaces.
- We do not perform repairs during severe weather.
- Authorization from a property owner or management.
- Repair work done in a parking lot or at your requires permission.
- We do not do repairs in areas restricted by law.
Common Questions
Service Area
Our primary service area is greater Grand Rapids and includes Comstock Park, East Grand Rapids, Grandville, Kentwood, Walker, and Wyoming
Our secondary service area is provided by our Belding location and includes: Belding, Greenville, Ionia and the sorrounding areas.
Contact us if you have any questions about where we provide services.
