HOW TO: Fuel Tank Strap Replacement - Toyota FJ Cruiser Forum
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post #1 of 20 (permalink) Old 05-13-2017, 06:21 PM Thread Starter
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HOW TO: Fuel Tank Strap Replacement

This is a guide on how to replace the gas tank straps. I noticed one day while walking up to my FJ that the OE plastic gas tank skid was crooked. It didn't take too long to discover that one of my gas tank straps had broken! It looked to be very corroded, which surprised me a little because how clean I usually keep the underside of the FJ, there isn't a whole lot of rust. I'll get to why I think it broke near the end of these posts. My FJ is a very early March '06 build, so I imagine this could potentially be a more prevalent problem on FJ's in the future. Keep an eye on it!

Initially I researched a little but couldn't find a how-to or any part numbers. This has happened on a few member's FJ's but pretty rarely. The straps and procedure for each are for the most part identical. I'll show you how to do one, it's really simple but while looking for a solution it's nice to have pics and part numbers of everything. It can be done easily with a simple set of hand tools and a jack. Lets get started.

The problem:
HOW TO: Fuel Tank Strap Replacement-20170501_115305_zpsnousthyt.jpg

My temporary solution
HOW TO: Fuel Tank Strap Replacement-20170502_125401_zpsq4wte0pb.jpg

Last edited by Iconic_; 12-03-2017 at 01:19 PM. Reason: Broken picture links
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post #2 of 20 (permalink) Old 05-13-2017, 06:21 PM Thread Starter
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Re: HOW TO: Fuel Tank Strap Replacement

The permanent fix:
The ratchet strap lasted me 2 weeks until I got parts and time to install them. The new OE part numbers you will want are:

77601-35110 - Front strap
77602-35050 - Rear strap

Which can be found on this diagram and come out to be about $90 before shipping: https://parts.conicellitoyotaofconsh...omponents-scat

As it turns out, the rubber fuel tank protectors are included with those part numbers as an assembly. Now, there is a non-oem kit on a few websites for a bit cheaper. I decided to stick OE, they lasted me 11 years after all. If you get an aftermarket variant feel free to let me know and post in this thread, I'm curious what they look like.

Here are what the new parts look like, I decided to just do both while I'm at it.
HOW TO: Fuel Tank Strap Replacement-20170513_155502_zpsnjdqfyth.jpg

First you will want to remove the fuel tank shield retaining strap as noted in the picture below. I have no idea what this thing is actually intended to do but it makes life easier if you remove the 2 nuts from the body side. (circled in blue)
HOW TO: Fuel Tank Strap Replacement-1_zpskq8oqox0.jpg

Then you will want to go ahead and remove the plastic fuel tank shield. There are 4 nuts, 2 are pictured below. Before doing so you will need to carefully remove your method of supporting the tank. (if any) In my case I took off the ratchet strap since my fuel level was practically empty and there wasn't a whole lot of weight.
HOW TO: Fuel Tank Strap Replacement-20170513_160022_zps6nvcwxtv.jpg

Here is what it looks like fully removed including the retaining strap:
HOW TO: Fuel Tank Strap Replacement-20170513_161113_zpslemmhjeq.jpg

Once removed, use a jack to support the tank and push it back up a little bit:
HOW TO: Fuel Tank Strap Replacement-20170513_161501_zpswbbw7lo2.jpg

Then remove the pin from one side of the strap, located near the center of the vehicle by the driveshaft:
HOW TO: Fuel Tank Strap Replacement-20170513_164002_zpsayczxcej.jpg

Then unbolt the remaining side of the strap, this bolt was a pain for me to remove because how the bracket is constructed it sits in water and mud its whole life. Spraying with WD40 or something better makes a world of difference. You can easily shoot it horizontally inside that welded-on bracket and cover the threads inside the frame.
HOW TO: Fuel Tank Strap Replacement-20170513_161628_zpseojez0dy.jpg

Finally, install the new strap! Exact procedure but reversed, nuthin' to it as I'm sure you are an expert by now. You may need to jack the tank up a bit more to fit the new one on.
HOW TO: Fuel Tank Strap Replacement-20170513_170128_zps26jw2qm9.jpg

When you have that strap on, repeat for the other side (if you choose to replace both) and relocate the jack as necessary to support the tank.

Once finished reinstalling the plastic shield, and you've double checked that you bolted on the tank shield retaining wire doohickey, grab a cold one and enjoy your hard, money-saving work!

Last edited by Iconic_; 12-03-2017 at 01:32 PM. Reason: Broken picture links
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post #3 of 20 (permalink) Old 05-13-2017, 06:22 PM Thread Starter
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Re: HOW TO: Fuel Tank Strap Replacement

Here is my broken strap. (rearmost) All of that junk is dirt and rusty metal chunks that were found in-between the metal strap and rubber tank protector. It looks like the tank protector is collecting dirt and water between itself and the strap which is accelerating the corrosion in that area.
HOW TO: Fuel Tank Strap Replacement-20170513_164147_zpsu6nflsjx.jpg

Yep, the metal strap still looks pretty shiny further under the protector:
HOW TO: Fuel Tank Strap Replacement-20170513_171103_zpsgqtrzhbk.jpg

So I could see it being beneficial to cut the rubber protector back a few inches or maybe zip tieing it down, couldn't hurt as long as you do it where the tank doesn't rub. I didn't make any modifications to mine however, but will keep an eye on that area.
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Last edited by Iconic_; 12-03-2017 at 01:34 PM. Reason: Broken picture links
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post #4 of 20 (permalink) Old 05-13-2017, 06:49 PM Thread Starter
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Re: HOW TO: Fuel Tank Strap Replacement

If you couldn't tell from the previous pics, this was the problem area that I will watch for on the new strap:
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post #5 of 20 (permalink) Old 05-13-2017, 08:19 PM
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Re: HOW TO: Fuel Tank Strap Replacement

Something to check next time I'm under the FJ
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post #6 of 20 (permalink) Old 05-13-2017, 08:32 PM
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Re: HOW TO: Fuel Tank Strap Replacement

Bonus Round: paint the new straps before assembly.

Because an extra coat of protection is always worthwhile.

Kind of like the suspension arms, or the black steel wheels - they come covered in a very good black coating, but one that will eventually begin to allow corrosion at all of the sharp edges, and around any welds, which a coat of black paint over will definitely help prevent/delay.


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post #7 of 20 (permalink) Old 05-13-2017, 09:11 PM Thread Starter
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Re: HOW TO: Fuel Tank Strap Replacement

Quote:
norm356 previously said: View Post
Bonus Round: paint the new straps before assembly.
I thought about it, and it probably would have been worth it, but I didn't do it.
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post #8 of 20 (permalink) Old 05-13-2017, 09:25 PM
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Re: HOW TO: Fuel Tank Strap Replacement

Nice job, thanks!
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post #9 of 20 (permalink) Old 05-14-2017, 06:33 AM
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Re: HOW TO: Fuel Tank Strap Replacement

Since it is now installed, and not really worth taking back off just to paint, you can just liberally coat it with fluid film protectant, in place, and touch up occasionally over the years and doing that it will last far longer than the original one did.

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post #10 of 20 (permalink) Old 09-26-2017, 04:48 AM
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Re: HOW TO: Fuel Tank Strap Replacement

@Iconic: I found a broken rear strap as well. I have have a 14'. No corrosion, and I have skid plates.
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