Steps to Repair a Truck Fuel Tank Thread

Continuous screwing and unscrewing of a truck's fuel tank cap will eventually cause the threads to wear out. These worn out threads will prevent you from properly closing the fuel tank of your truck. If you cannot properly close the cap on your fuel tank, you have a potential fire hazard.

Steps to Repair a Truck Fuel Tank Thread:

Step 1: Disconnect the truck battery. Ensure that you have a fire extinguisher nearby. Ensure that you have a tap and die set and a screwdriver. You will also need a new fuel tank filler.

Step 2: Remove damaged rubber from your truck fuel tank cap. Using the die bit in your tap and die set, cut the damaged rubber. Make each groove in the damaged rubber thin and parallel to the truck fuel tank cap's bolts.

Step 3: Open the fuel cap door of the truck. Remove the retaining bolts. Remove the rear plastic covering the location of the fuel neck filler. Remove the bolts found under the plastic connecting the fuel tank filler to the gas tank. Using the die bit cut new threads for these bolts.

Step 4: Locate and disconnect the full neck filler. It is located near the fuel tank. Replace the old fuel neck filler with the new one.

Step 5: Tighten the bolts connecting the fuel neck filler to the gas tank. Refit the bolts that connect the fuel neck filler to the gas tank. Replace the plastic covering the location of the fuel neck filler. Replace the retaining bolts to the fuel cap door.