Should You Worry About Small Cracks in Your Fuel Tank? The Risks Explained

You should be very concerned with small cracks in your fuel tank — find out why within. These cracks can lead to catastrophic fuel leaks. This leads to not only the unnecessary consumption of gasoline, but increases the likelihood of flammable liquid hazard.

Even small cracks can lead to dangerous vapors accumulating, impacting both air quality and public health. As time passes, these fissures can grow when under stress or heat, aggravating the issue and possibly resulting in expensive tank replacement.

You don’t want to let small problems like this develop into major hazards that put your safety and productivity at risk.

Key Takeaways

• Identify small cracks in fuel tanks before they have a chance to progress to bigger problems. Steer clear of expensive repairs by keeping up with regular inspections and taking care of any small issues before they become big problems.
• Know that frequent reasons for fuel tank cracks don’t always point to blame material fatigue, environmental impact, impact damage, and manufacturing flaws. Understanding these risks is the first step to taking preventive action.
• These seemingly small cracks can be potentially deadly. Take heed of fuel leaking, fire hazard, environmental contamination and engine running quality concerns. Taking action on cracks as soon as possible can reduce many of these risks.
• Employ detection measures including visual inspection, pressure testing, and ultrasonic testing to detect cracks early before they develop into more severe problems. Early detection is less expensive and it will help keep you and others safe as well.
• So, make sure you’re fueling with the appropriate type and additives to limit your vehicle’s risk of cracking. Be sure to consider fuel quality and compatibility with your vehicle’s fuel system before making the switch.
• That’s why proactive maintenance is so important. Use protective coatings, avoid aggressive driving habits, and consult automotive experts to avoid cracks and increase the longevity of your fuel tank.

What Causes Fuel Tank Cracks?

Fuel tank cracks have many causes, all working individually, or in conjunction to create the perfect storm. Understanding what causes these cracks is crucial for protecting cargo from damage and ensuring safety on the road.

Material Fatigue and Stress

With constant use, fuel tanks go through stresses repeatedly over long periods of time. Environmental factors and wear and tear can wear down materials. This is particularly the case in locations where the tank commonly rubs against adjacent components or is subjected to significant vibrational energy.

The impact of changing temperatures is another factor. Severe summer heat or harsh winter cold temperatures can make the tank’s material expand and contract, or flex. This constant flexing leads to stress cracks on the tank.

Metal tanks, shown here under a 1966 Ford Galaxie 500, are rust-prone and fail from fatigue easily. Tanks made out of plastic, introduced in the 1980s, are prone to cracking when exposed to UV light, an issue frequently observed on 2006 Honda Civic Hybrids.

Improper installation, such as not properly securing tanks that are mounted above the rear axle, can add stress, thus increasing the chance of cracks forming.

Environmental Factors Influence

Local environmental conditions are the most significant factor influencing tank durability. Fuel metal tanks exposed to salt, particularly in coastal or snowy areas, are corroded.

For example, plastic tanks can undergo stress cracking or brittleness under the influence of long-term UV exposure. Vehicles located in hotter, sunnier climates are likely to experience more rapid material deterioration.

Because material weld-together cannot compress, moisture infiltration rapidly wears down material especially in areas where the atmosphere is consistently humid.

Impact Damage and Road Debris

Physical damage such as punctures caused by road debris or physical damage from poorly maintained roads is the second most common cause. As gravel, branches or other debris strikes the tank, it often starts pressure cracks.

Routine inspection following such an impact is critical to prevent undetected damage which could lead to catastrophic failure.

Manufacturing Defects

Defects that occur during the manufacturing processes can lead to tanks that have built-in defects. Honda, for instance, did step up to admit faulty tanks in a limited batch of Civic Hybrids, but the timeline for cracking is still impossible to predict.

These defects highlight the importance of quality control and recall processes to address safety concerns.

How Cracks Develop and Worsen

What might be missed is the propensity for small cracks—in a fuel tank, for example—to develop into much larger cracks and environmental disasters. Age & Routine Use Over time, age and routine use can exacerbate these factors, allowing them to deepen in precision-formed plastic tanks.

In fact, according to Vehicle and Transportation companies, cracks typically begin developing on tanks after 12 years or 132,000 miles. What starts as an almost undetectable crack can grow, creating bigger openings for water intrusion. Like all stages of this progression, it is largely a function of the fuel pressure and the tank’s continual bombarding with vibration while in use.

Cracks around brass inserts and tank mounts are high priority crack development areas. These neighborhoods experience the highest levels of stress, creating greater challenges in making necessary repairs.

Environmental factors are just as important, if not more so. Extreme heat will lead the plastic to expand, cold weather can make it more brittle, worsening cracks that are already present. Extended contact with UV light and water will cause further deterioration of the material, speeding up the destructive process.

All of these things can turn a relatively minor problem into an expensive repair or replacement. Hopeful estimates range anywhere from $900 to more than $1,500 based on how deep the cracks go.

Being able to identify when cracks are getting worse is important. Watch out for a pungent fuel smell, detectable fuel leaks, or loss of fuel economy. Responding to these indicators as soon as possible is key.

Home remedies such as a soldering iron or Permatex plastic tank repair epoxy will offer temporary relief. These approaches aren’t effective for all tank types and can prove ineffective over time. Prevent future damage by acting quickly with timely repairs! This can help mitigate leaking from the tanks and, in extreme situations, may prevent fires due to fuel exposure following an impact.

Risks of Small Fuel Tank Cracks

Though difficult to detect, these small cracks in a fuel tank can lead to a plethora of safety hazards. These cracks have major environmental and economic impacts as well. It is critical that these risks be addressed as soon as possible so that vehicle owners are not subjected to long-term, negative effects.

Fuel Leakage and Wastage

Not only is a potential fuel leak dangerous, even the tiniest crack would leak fuel enough to waste thousands of dollars over time. This wasted fuel is bad for your budget and bad for the planet.

Leaked gasoline can contaminate the surrounding soil and water, harming local ecosystems and possibly poisoning groundwater. According to the EPA, for example, a single car leaking one gallon of fuel poses significant risks to the vegetation and wildlife in the impacted area.

Keep a close eye on your small fuel tank levels. Watch for any abnormally large drops to identify leaks early and mitigate major issues.

Fire and Explosion Hazards

Because gasoline is extremely flammable, even minor leaks can present hazardous vapor levels. These vapors can explode or catch fire from a simple spark or extreme heat, resulting in serious injury or death.

In the case of a crash, a tank with existing cracks would increase the risk of fire quickly becoming fatal. If you think there is a leak, don’t wait.

Contact us today, we can help. Park in a safe location and check with a mechanic to reduce your risk.

Environmental Contamination Concerns

Fuel leaks are more than a mechanical hiccup—they threaten clean air and water for decades. Repairing soil or water systems contaminated with gasoline can take decades — if it’s even possible.

Proper cleanup and disposal of leaked fuel is critical to limiting damages. Knowing the ins and outs of local regulations can help you avoid breaking the law and facing liability.

Engine Performance Issues

Cracks that form may lead to harmful leaks that can compromise the engine’s fuel supply. This leads to issues including engine stalling, difficulty starting the vehicle, and lower fuel economy.

Over time, the symptoms can progress, resulting in deeper and much more expensive repairs. By keeping a close watch on engine performance, fleets can catch problems before they become serious and costly.

Increased Repair Costs

Similarly, ignoring small cracks can result in more serious issues, such as damaged fuel lines or the need to replace the entire tank. Since repairs for a cracked tank usually run about $900, tackling the problem before it escalates will save you hundreds.

If you are a Honda Civic Hybrid owner, make sure to have your tank inspected immediately and report all cracking tank issues to the NHTSA.

Detecting Small Cracks Early

Detecting small cracks on your commercial fuel tank before they turn into a bigger issue could save you from expensive repairs and help you avoid dumping your fuel. These cracks can form due to usage, creation flaws during the manufacturing process or stresses built up over time.

Left unattended, small damage can worsen, risking fuel leaks, increased emissions and damage to the surrounding environment. Detect small cracks early. Early detection means those issues get treatment before they become worse, creating a higher risk of serious damage.

Visual Inspection Best Practices

Routine visual inspections are an easy and affordable first step to finding cracks. Use these best practices:

• Inspect the fuel tank for cracks or other deterioration.
• Look for any wet areas or fuel staining around the bottom of the fuel tank, fuel lines and any connections.
• Remove and inspect the fuel cap to make sure it seals tightly and doesn’t have any cracks or tears.
• Be on the lookout for abnormal fuel smells, which can be a sign of a fuel leak.

Pressure Testing Methods

Pressure testing is the most efficient method to find small or hidden cracks. This technique requires highly specialized equipment to safely pressurize the tank and detect areas of weakness.

This is why regular testing, particularly following repairs or reconditioning, is so essential. Getting professional help is your best bet to guarantee accuracy, since incorrect testing can result in false positives or even further damage.

Dye Penetrant Inspections

Dye penetrant inspections, often used in aerospace, draw attention to cracks through a three-step process. This technique is inexpensive and well-suited for at-home, early detection.

Wet particle dyes are very effective at locating surface cracks, while dry particles are more adept at detecting subsurface defects. Remember—groundwater safety Every time you apply, ensure that you are following strict safety protocols.

Ultrasonic Testing Options

Ultrasonic testing provides a non-intrusive method to detect cracks without having to dismantle the tank. Today, this state-of-the-art approach has the ability to detect even the tiniest cracks.

It takes highly trained technicians and specialized gear. By investing in this technology, it allows for more comprehensive and detailed inspections.

Fuel Type and Crack Formation

The nature of the fuel you’re using factors heavily into your risk of fuel tank cracking. While gasoline and diesel are the most widely known fuels today, each have their own distinct chemical makeup. These properties influence how they interact with tank materials, like plastic or steel.

For ag producers looking to replace or add plastic tanks, these provide a lightweight, economical alternative. However, they are much more susceptible to cracking with age than steel tanks.

Gasoline vs. Diesel Effects

Gasoline’s high vapor pressure contributes to increased pressure return line crack formation. This coincides with gradual weakening of materials, particularly plastic. Diesel, being less volatile, poses a different challenge: its oily consistency can degrade certain seals and coatings over time.

The Honda Civic Hybrid illustrates these vulnerabilities. Numerous affected owners have stepped forward detailing their experiences with incurring cracks/leaks in their tanks as early as 12 years or 132,000 miles. This problem highlights just how important it is to know what kind of fuel your vehicle needs and keep your tank in shape.

Ethanol Blend Considerations

Ethanol blends, which comprise 10 percent of most gasoline sold today, can further worsen tank material problems. Since ethanol absorbs moisture, that increases the chance of internal corrosion. This is especially problematic for any older vehicles or tanks not originally built for these alternative fuels.

It is important to check your vehicle’s compatibility with higher ethanol content and local/state fuel regulations. For instance, the use of higher ethanol percentages has been shown to increase wear in plastic tanks, causing cracks to form.

Additive Impacts on Tank Integrity

Fuel additives are particularly noteworthy in their impact on crack formation. Although these additives help reduce engine deposits, some of them can cause degradation of tank materials after extended exposure.

Using the best quality fuel and knowing what additives are in your fuel can reduce the risk.

Preventing Cracks and Damage

Fortunately, taking these proactive steps can greatly decrease the likelihood of cracks and damage to your fuel tank. Proper, consistent care is key to keeping your tank safe and damage-free for years to come. Each preventive measure goes a long way towards providing peace of mind while maximizing your tank’s lifespan.

Regular Tank Inspections

Regular inspections are fuel tank maintenance 101. Key components to check include:

• Fuel lines: Look for cracks, wear, or leaks. Change routes every 15,000 – 30,000 miles to prevent fracture.
• Check metal tanks for rust or corrosion, which can weaken the structure.
• Ensure these are intact to prevent fuel leaks.
• Fuel levels: Sudden drops might indicate leaks or damage. Globally, water intrusion damages 11% to 42% of fuel systems, making this a crucial check.

Protective Coatings Application

Protective coatings are an important line of defense in protecting against rust and corrosion. A high-performing coating defends metal tanks from damaging moisture, helping to prolong the life and effectiveness of the valuable assets.

Use materials that are intended for fuel storage and make reapplication of coatings a part of regular maintenance. To prevent gelling in winter, additive solutions keep it flowing and options like fuel line heaters are available.

Safe Driving Habits

Safe driving practices help protect against fuel tank punctures. Retread Tires Preventing Cracks and Damage. Avoid potholes and rough roads to avoid impact damage.

Keep an eye out for cracking or damage to the roadway and keep a safe distance from material on the roadway. These subtle practices avoid unnecessary wear and tear, which is especially relevant when we experience seasonal transitions.

Repair or Replace?

Whether you should repair or replace a cracked fuel tank depends on multiple factors. These factors dictate things like the crack’s severity, the tank’s overall condition, and long-term safety considerations. Knowing these things will allow you to make an informed decision that protects taxpayer dollars while keeping people safe.

Assessing Crack Severity

Measuring the full scope of damage with precision and detail is always paramount. Follow these steps for evaluation:

• Check the size and location of the crack. An even bigger or misaligned crack could destroy the entire conveyance.
• Inspect for fuel leakage. It turns out even small leaks might be a big deal.

Evaluate the tank’s condition: Repairability Factors Older tanks with significant dings, corrosion, or multiple cracking instances are usually less amenable to repair. Expert evaluation makes for a better decision process, particularly when it comes to unseen damage or structural issues.

Repairing Options and Limitations

For small cosmetic repairs, like dents and scratches, repair is a more feasible option. There are effective products, for instance, POR 15 can seal cracks and protect against deterioration, and welding can cure structural issues.

Even these improvements aren’t perfect. Sometimes temporary repairs just break down, particularly when exposed to extreme heat or pressure, and subpar materials can cause repeated issues. Unsafely undertaking DIY repairs, including cutting open fuel tanks, can lead to injury and property damage.

When Replacement Is Necessary

When cracks are deep or repairs are inconsistent, replacement becomes essential. A new tank removes the danger of leaked or ignited fuel, which occurs in roughly 10 percent of defective tanks in collisions.

While the $900 price tag might sound high, it’s a one-time cost for total peace-of-mind. Choosing tanks from known manufacturers sets the standard for durability and safety for years. Replacing a tank proactively, before it becomes a big burden, saves large and inconvenient repair costs in the future.

Conclusion

Here’s what to know about these small cracks, why you shouldn’t overlook them, and what could happen if you do. They can lead to corrosion, leaks, wastage of fuel or even result in fire hazards. Knowing how to recognize them and their potential risks can keep you safe and save you money. Consistent monitoring and maintaining your small crack fuel tank go a long way in preventing larger problems.

If you see any cracks or other indications of wear, do something about it immediately. These repairs or replacements could be a financial burden now, but they save you from much larger costs in the future. By taking preventative measures such as using the correct fuel and not overfilling the tank, you can avoid small cracks developing in the future.

Take a cue from the automotive pros, and regularly care for your fuel system. You’re doing the right thing by addressing minor cracks today to avoid future dangers down the road.

Frequently Asked Questions

1. Should I be worried about small cracks in my fuel tank?

Yes, even small cracks can lead to fuel leaks, fire hazards, or environmental damage. They can expand with time and create hazardous impacts on vehicle safety. Fix them right away to prevent expensive damage, safety hazards, and emergencies.

2. What causes small cracks in a fuel tank?

Small cracks can develop from general wear and tear, exposure to severe temperature changes, vibrations, or subpar materials used in production. Together, these myriad factors erode the integrity of the tank, resulting in cracks.

3. How can I tell if my fuel tank has small cracks?

Signs may be a fuel smell around your vehicle, leaks that you can visibly see, or deterioration of fuel economy. A combination of regular inspections and proactive repairs can ensure these cracks are found and addressed promptly.

4. Is it safe to drive with a cracked fuel tank?

Should you be worried, yes, you should not drive with a cracked fuel tank. Fuel leaks due to a cracked fuel tank can increase fire hazards, environmental damage, and vehicle damage. Repair as soon as possible so that it doesn’t lead to more damage.

5. Can fuel type affect the formation of cracks?

Yes — some fuel types, such as high ethanol blends, can increase the risk of tank corrosion. Since ethanol increases water absorption, the tank lining is eventually corroded and cracks develop over time, mostly in older vehicles.

6. Should I repair or replace a cracked fuel tank?

That all depends on the size and location of the crack. In some cases, small cracks could be repaired or even preventatively sealed with the relevant expertise. Major damages usually necessitate a complete swap out to maintain safe infrastructure.

7. How can I prevent cracks in my fuel tank?

Proper care, such as by not overfilling the tank and parking in shaded places, can reduce risks. Safeguard against hazardous cracks by closely inspecting your tank regularly, and take care of any minor issues before they escalate to severe damage.