2002 Chevy Silverado Fuel Tank Repair

  • V8
  • 2WD
  • 125,000 MILES
My 2002 Silverado had an 1/8" hole drilled in the plastic gas tank to steal the fuel. I have been told those tanks have a plastic liner in them. I would like to patch the tank and have found a kit from Caswell that will do it but I am not sure about the liner. Is it attached to the inside of the tank? Will I run the risk of getting gas under the liner and not to the fuel pickup? I really don't want to pull the tank and spend the 700.00 the dealer wants for a new one. Also does anyone make a metal "shield" that could be put over the tank so this can't happen again? I know thieves will be theives but I would like to slow them down.
Do you
have the same problem?
Monday, March 15th, 2010 AT 2:11 PM

1 Reply

There's no liner to worry about, but sand the tank in the area first to remove the shiny surface so the patch material will stick.

My mother hit a huge piece of metal on the highway with her Grand Caravan. It tore off the rear heater hoses and punched a hole in the tank making a 3" x 1" cut two sides of a rectangle. It was up high enough that she only lost 3/4 tank of fuel. By leep-frogging it with my car, I nursed it home 7 miles with no coolant. Half way home, I crawled underneath, sanded the tank in the area, (metal tank), and built up a temporary patch with Mopar RTV gasket sealer, (the harder, better-sealing gray stuff). Never smelled any fumes from that point on.

While repairing the heater hoses at home, I decided the "temporary" patch was vulnerable to rocks, so I added a thin piece of tin over it. Decided the tin was vulnerable to corrosion so I added another layer of gasket sealer. That was 20 years ago! It's still my dailer driver and has never had a sign of leaking. I always overfill the tank. I've even given up watching for a good used tank. The hole is WAY bigger than 1/8".

You might consider using RTV, (room temperature vulcanizing) gasket sealer, and for good measure, run a self-tapping bolt with a washer into the hole with it.

Not sure what rare elements your tank is made of, but for $700.00, you can get a half dozen good tanks from the salvage yards.

Was this
Monday, March 15th, 2010 AT 2:48 PM

Please login or register to post a reply.

Sponsored links