Fix A Flat Tire Yourself With A Tire Plug Kit
Photography by John Cappa
A tire repair plug kit can be used as a fast, easy and effective method of fixing most 4×4 flat tire punctures. Tire plug kits are affordable, readily available and compact enough that one can be stored easily in every 4×4. When you consider that the most common off-road vehicle failure is probably a flat tire, it starts to make even more sense. Come to think of it, a flat tire is likely the most common on-road vehicle failure too. Of course you can carry and install a spare tire, but a tire plug can save a lot of time and effort. Read on and we’ll walk you through the basics of plugging a punctured tire as well as what to look for in a tire repair plug kit.
There are lots of tire plug kits to choose from. Some have more features than others. Look for sturdy T-handle tools with replaceable ends along with spare tool bits and plenty of tire plugs. A small container of lubricant is also helpful.
Best Flat Tire Repair Plug Kit
There are a multitude of different tire plug kits available. Which kit you choose will depend on your budget and how advanced you are at repairing punctured tires. If it’s your first tire plug kit, stick with the basics. Look for sturdy T-handled tools with replaceable tooling. You’ll also want your kit to include plenty of tire plugs. Lubricant, pliers, razor blades and safety wire can also be useful items in a tire plug kit, but they may not be necessary for your application.
It’s not at all uncommon for a tire to catch a single screw, nail or bolt. If the object enters the tire fairly straight then you’ll have an easy repair to make. Larger punctures can be trickier, but they aren’t impossible as long as the hole isn’t too big.
Is Your Flat Tire Repairable
It’s best to stop your 4×4 in a safe place as soon as you notice that your tire is deflated or deflating. Driving on a tire with no air pressure can damage the tire and wheel. Assess the damage to the tire and find the leak or punctured area. Pull the vehicle forward or back just enough to where you can access the puncture. Sometimes it may be easier to remove the tire and wheel from the vehicle, which will give you full access to the punctured area. In most cases a hole in the tire tread area made from a screw, nail or small bolt can be easily repaired with one tire plug. Bigger punctures caused by larger items may not be repairable. If the hole or tear in the tread is more than a 1/2-inch in length or diameter you’ll likely need to install your spare tire and see if a tire shop can properly fix the flat tire.
A sidewall puncture is much more difficult to repair than a tread puncture. You should only repair a sidewall to get you off of the trail. A cut like this would likely need to be stitched up with safety wire and plugged a dozen times or more. You’re better off installing the spare tire.
Can You Repair A Tire Sidewall Puncture?
Sidewall punctures are very common off-road. In many cases a 1/2-inch-long or shorter sidewall puncture can be temporarily repaired with a plug kit, however you should not run the plugged tire at higher speeds or on the road at any speed. Tire plugs used in a sidewall repair can get pulled out by rubbing on the terrain or spit out as the tire sidewall flexes. Larger sidewall punctures can be repaired if you are in a pinch, but they require more skill and driving finesse to keep the repair in place. Massive gashes in a tire sidewall have been repaired by stitching the tire back together with safety wire, the same way you might stitch up a wound. You’ll need an excessive number of tire plugs to make a repair like this so make sure you have enough before getting started.
Unbroken and unbent screws and bolts can simply be unthreaded from the tire tread. Nails and other puncture items will need to be pried and pulled from the tire.
Remove The Offending Item From The Punctured Tire
Regardless of what’s stuck in your tire, you’ll want to remove it as cleanly as possible, without doing further damage to the tire carcass. In some cases you will be able to simply unthread bolts and screws from the tire. Nails and other objects will generally require prying and pulling with a small prybar or blade screwdriver and pliers. If the tire was punctured by a longer larger item, make sure the wheel is not damaged. It’s possible for larger items to puncture the tire, continue on and punch through the wheel too.
Clean out and open up the puncture with the reaming tool. Follow the path of the original puncture so that you don’t make a larger hole than you need to. A dab of lubricant on the tip of the tool makes this process easier.
Prepping A Punctured Tire For Repair
All quality tire plug kits include a reaming tool. It is used to open up and clean out the tire puncture. It also roughens the surface so the tire plug can seal the hole more effectively. A bit of the included tire repair lubricant can be put on the tip of the tool to help open up smaller punctures. Ream the puncture until it’s relatively easy to insert and remove the tool. If the puncture hole is too small and not prepared properly, you’ll never get a tire plug inserted. Leave the reamer in the tire to help retain any remaining air while loading a tire plug into the insertion tool.
Properly load the tire plug into the tool. The plug should be threaded halfway through the end of the tool. Smear a dab of lubricant on the tip. This will not only help insert the plug into the tire, it will help release the plug from the tool.
Insert the plug into the tire and follow the direction of the puncture so that at least 3/4- to 1-inch of the plug is inside the air camber of the tire. Push the tool flange forward against the plug and quickly remove the tool, leaving the plug in the tire.
Plugging A Punctured Tire
Smear lust a bit of lubricant on the tip of the plug insertion tool. This will help insertion of the tool and help release the plug when the tool is removed from the puncture. Remove the reamer and quickly insert the tire plug with the proper tool. Make sure that at least 3/4- to 1-inch of the plug is inserted into the air chamber of the tire. Work the tool back and forth if you need to, but do not twist the tool. Once the tire plug is properly inserted, quickly yank the tool straight out, leaving behind the tire plug. Repeat as needed for larger punctures.
Check the repair for leaks by spraying it with soapy water or any liquid you have on hand. If it checks out OK you can trim the excess plug sticking out of the tire with a razor blade or sharp pocket knife.
Finishing Your Flat Tire Repair
Refill the tire to the proper tire pressure. Listen for leaks as you are refilling the tire. Spray soapy water or pour whatever liquid you have over the puncture to check for leaks. If you see bubbles you may need to insert another tire plug into the puncture. Once you are sure you have properly sealed the tire you can use a razor or sharp pocket knife to trim the excess tire plug smoothly to the tread surface. Have a tire shop inspect the tire and properly repair it from the inside when you return to civilization.
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