Fuel Sender Repair Gone Wrong...

[Spiderman80]

I was rebuilding the sending unit in my gas tank and when returning it to the top of the tank after the repair, I snapped one of the bolts at the top of the tank. Anyone ever replace one of these? I really don't want to replace the tank because of one missing bolt. I'm tempted to just leave it alone as the other ones are plenty tight. I don't think I'm at risk of leak or vapors escaping. Just looking for some advice...

[18Fiatsandcounting]

My Spidey-sense is not tingling on this one, and I think you'll be fine with just two bolts on the sender/fuel line unit. The fuel pump will still pump, the fuel return line (if you have one) will still be fine, and your vapor accumulation system should still be OK. Check every so often for the smell of gas in the trunk, and if there is none, you should be fine. If you do sense you're leaking vapors because of the one missing nut, you could try a little bit of fuel-impervious gasket sealant around the gasket (Permatex or the like).

-Bryan

[Spiderman80]

Thx 18Fiatsandcounting! Just needed a reality check... Much appreciated.

[18Fiatsandcounting]

Although I don't think it's necessary, another option is to remove the fuel sending unit, stuff a sticky rag into the hole to collect metal chips, drill out what remains of the stud, and then tap threads in the hole to accept a new bolt. So, you'd end up with the original two studs and two nuts, and then one bolt screwed into the top of the tank for the third "hold-down" for the sending unit.

-Bryan

[spider2081]

I think a 1980 Spider fuel tank sender has 6 studs retaining it to the tank, so having one missing probably a non issue.

[Jon124]

I’ve had the same problem and I can confirm it will leak fuel with only 5 of 6 studs in place. I fixed mine by coating the gasket on both sides with permatex aviation form a gasket. It has been leak free for 4 years now.

[spider2081]

I’ve had the same problem and I can confirm it will leak fuel with only 5 of 6 studs in place. I fixed mine by coating the gasket on both sides with permatex aviation form a gasket. It has been leak free for 4 years now.

I agree that is a better way

[18Fiatsandcounting]

I’ve had the same problem and I can confirm it will leak fuel with only 5 of 6 studs in place. I fixed mine by coating the gasket on both sides with permatex aviation form a gasket. It has been leak free for 4 years now.

I agree that is a better way

Yes, agreement also from me. And, I don't know what I was thinking when I mentioned 3 studs... It should be 6.

-Bryan

[TFichter]

I had a similar situation and lived with it for awhile. However, i could smell gas at times. If your broken stud has some threads remaining as i did, I came up with a solution that works. Purchase an 8/32 threaded rivet- i had to buy a bag for $8. This will thread on to your partial stud. Next drill out the corresponding hole on the fuel sending unit so that the rivet can pass through it. Now you can bolt the rivet to the partial stud. The rivet will most likely be too long to get compression so i used a stack of washers to make the correct tightness. I suppose you could cut the rivet shorter as well but the stack of washers managed to work and keep the integrity of the rivet intact. This worked like a charm. I was fortunate to have broken my bolt halfway up to allow me to repair it this way.