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RTM Fuel Tank Stud Repair Kit: 1g DSM AWD/Galant/3000GT

RTM Fuel Tank Stud Repair Kit: 1g DSM AWD/Galant/3000GT
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If you own a 1g AWD DSM (or Galant VR4 or 3000GT) and you've ever taken a good look at your fuel pump sending unit, we hope you had a strong stomach 'cause they can get downright nasty with corrosion. Sitting on top of the fuel tank in a sunken area, any water that finds it way up there tends to pool right there and, over time, this inevitably leads to corrosion of the various metal components. Most famous for corrosion are the studs and nuts that fasten it to the tank and also the thin-walled steel tubing that makes up the fuel feed line. This corroded sending unit is bad enough if it's just sitting there but the minute it's disturbed (to change the fuel pump for example) watch out! Can you say SNAP! 'Cause that's a very common outcome to the studs and fuel feed line when any pressure is applied to them. If this is the situation in your case, all hope is not lost, 'cause RTM has your solution.

We've designed two different repair kits for the fuel pump sending unit:
1) A repair kit that allows you to replace any broken or missing studs.
2) A repair kit that replaces a damaged stock fuel feed hard line.
We sell each kit separately. This particular kit relates to the first kit: the Fuel Tank Stud Repair Kit. For details on the FPSU Feed Line Repair Kit please refer to the "Related products link near the bottom of the page.

The principal components of this repair kit are two C-shaped repair plates that are fastened underneath the top of your fuel tank and contain threaded holes (in precise locations) to accept up to six new bolts to replace any missing studs. These C-shaped repair plates are sealed to the underside of the top of the fuel tank with O-rings which provide a leak-proof seal. This repair kit can be used to replace ANY number of broken studs on top of your fuel tank, even ALL SIX of your original studs can be replaced with brand new stainless steel bolts. So no need to worry yourself about snapping those feeble, rusty studs. (We can't help but believe there exists an engineer at Mitsu with a sick sense of humour. How else can the choice of those ridiculous feeble studs be explained)?

Also included with the kit are: 

  • Four O-rings for sealing repair plates to tank. 
  • Four 5mm stainless button-head screws to attach the C-shaped repair plates to the tank.
  • Allen key for tightening above button-head screws. 
  • Six 5mm stainless hex-head bolts used to replace any broken/missing studs.
  • Two 5mm nuts for above bolts.
  • 7/32" drill bit to drill holes for any new bolts being used to replace broken/missing studs. 
  • piece of 120grit emery paper for deburring holes.

The stud repair procedure requires that a special drill guide fixture be used. This fixture is designed to be positioned onto the top of your tank and act as a drill guide to allow you to precisely drill all the necessary holes into the top of your tank.

We consider this fixture to be absolutely essential to the repair kit and that it would be virtually impossible to drill holes in the correct places without it. Unfortunately, we no longer have any more of these drill guides (nor do we intend to ever make any more) and thus you'll need to somehow source your own (presumably by making one or having one made for you).

The fact is that the fixture does not get "consumed" in the repair so it can be used over and over again. In fact, enterprising individuals may even consider trying to rent their fixture out to others.

NOTE: The installation of this repair kit is fairly complicated, so full installation instructions are available on the RTM Forums under "RTM Product Information" at the top of the Forum. For a link to the RTM Forums, refer to the top of this page.

DSM (1990-94) AWD.
Galant (1988-93) AWD.
Stealth/3000GT (1991-99) AWD.

Several purchase options available.
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SKU 1K-FuelTankStudRepairKit-1gAWD
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