[Iconic_]

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:

My temporary solution :lol:

 

[Iconic_]

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.conicellitoyotaofcons...e/fuel-system-cat/fuel-system-components-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.

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)

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.

Here is what it looks like fully removed including the retaining strap:

Once removed, use a jack to support the tank and push it back up a little bit:

Then remove the pin from one side of the strap, located near the center of the vehicle by the driveshaft:

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.

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.

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! :cheers:

 

[Iconic_]

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.

Yep, the metal strap still looks pretty shiny further under the protector:

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.

 

[Iconic_]

If you couldn't tell from the previous pics, this was the problem area that I will watch for on the new strap:

 

[mikey]

Something to check next time I'm under the FJ

 

[norm356]

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.


N

 

[Iconic_]

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.

 

[Hannibal]

Nice job, thanks! :cheers:

 

[norm356]

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.

 

[Red Crow]

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

 

[Iconic_]

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

Hmmm that seems strange! Must've hit the skid offroad? Either that or a shop mechanic decided to hang from it while it was on a lift. :lol:

 

[Red Crow]

@Iconic: I googled Toyota broken fuel tank strap and it seems that Tundras and Rav. 4 have the same issue.

 

[picaman]

Yup just happened on my 07. Was wondering what was hanging down and finally got a break in the rain today to get under there. Thanks so much for this post and the part numbers! My last two were super easy: right and left window swipes and an new antenna grommet. I guess the fjs are toshow their age... I'm liking the 2020 Ford Bronco unless Toyota finally pulls the trigger on a full frame on body 2020 fj. No, I won't give mine up, 150,000 miles and still going strong!

 

[rossdaboss005]

I walked out to my car last night, and noticed something hanging down. Exact same thing. I've got mine bungie corded until the parts come. Thanks for the great post to follow! I've got an 07 FJ as well; time and mother nature taking her toll I suppose.

One question, regarding paint, what would anyone recommend? I was thinking a Rustoleum automotive spray paint. There's an undercoating specific paint. https://www.homedepot.com/p/Rust-Ol...ack-Undercoating-Spray-Paint-248656/202097270

Thanks in advance!

 

[picaman]

Thanks for the post, it was very helpful. I went with the aftermarket straps from spectrum industries. The fitment was perfect but they were uncoated. So I shot them up with some rustoleum. Just the uncoated straps with no other hardware was about $60.00 delivered.

 

[rossdaboss005]

Thanks for the post, it was very helpful. I went with the aftermarket straps from spectrum industries. The fitment was perfect but they were uncoated. So I shot them up with some rustoleum. Just the uncoated straps with no other hardware was about $60.00 delivered.

I'm going to be doing the same thing! Straps arrive today, going to paint them tonight, to install tomorrow. Hopefully the existing hardware stays intact!

 

[Iconic_]

Glad you guys are getting use from this thread! Replacement is not hard but having the part numbers in front of you and a mental picture of the process beforehand is always good!

 

[racefanmartin]

Thanks for the post, I am replacing my straps today. Pictures where great.

 

[FJtest]

I'm going to be doing the same thing! Straps arrive today, going to paint them tonight, to install tomorrow. Hopefully the existing hardware stays intact!

A quick misting with rattle-can paint over bare metal won't provide corrosion protection for long. I'd suggest 3-4 coats of a zinc-rich primer, baked, and then several top coats of a good enamel, with the whole strap oven-baked at 250F after the last coat is dry.

 

[Iconic_]

Thanks for the post, I am replacing my straps today. Pictures where great.

Glad this post is getting some use. I noticed the rubber isolators like to trap dirt against the strap. My buddy had to replace some on his '08 recently as well.