Broken stud on fuel tank

[Martyn]

Hi,

Lockdowned in Spain. A chance to do some long awaited work on car, or so I thought.

I replaced the fuel tank, but when refitting the sender unit one of the studs snapped off. It was literally the last turn of the last nut!!!!!!!!!!

What are the solutions? Drill out remainder of stud and use self tapping screw. Possibly also apply some gasket sealer. Replace the tank??

Alternatively I could test for leaks?? But would only leak when fuel sloshing around and then maybe that would happen some time in future (months or years) without me knowing.

Any ideas??

Cant do much for next three weeks anyway as everything closed here.

Keep safe.

[18Fiatsandcounting]

Breaking a stud like this does happen, but it's not the end of the world. I wouldn't go so far as to replace the tank, and I think your options are either:

1) live with only 5 of the 6 screws holding down the sending unit against the rubber seal (gasket). Might work well enough.
2) Drill out the broken stud and replace with a new screw as you suggest. If you do this, I would hold an oily rag or the like right under where you are drilling so as to catch any metal filings that would otherwise fall into the gas tank. Having that happen isn't the end of the world as there are several filters on the way to the fuel pump and engine, but still, try to minimize as best you can.

If it were me, I'd go with option 2.

-Bryan

[Martyn]

Thanks Bryan,

I think I will go for option 2 as you suggest. But need to wait until stores open here for the screw, which is going to be 26th April at the earliest!

Martyn

[spider2081]

I think I will go for option 2

I have done this in the past. Now I run a die over the studs to clean the paint out of the threads and open up the holes in the sender a few drill sizes. If I remember I used a 4 mm diameter screw about 10mm long does this sound correct?? Is your mail service operational???
email me a mailing address and I will ask a friend to mail you a couple. My email is: flyme194@gmail.com