Tire Repair: the full procedure
Repair a qualifying tread-area puncture with a combination patch-plug unit installed from inside the dismounted tire, never an outside plug-only or sidewall repair.
- Applies to: Tire technician.
- Frequency: Every approved puncture repair.
- Scope: Defines the repair process. Puncture-size and repairable-area limits defer to USTMA/RMA and TIA standards and the tire manufacturer.
What you need
- Tire machine
- Combination patch-plug repair units
- Low-speed buffer
- Vulcanizing cement
- Inner-liner cleaner
The procedure, step by step
- Dismount the tire — Remove the tire from the wheel so the inner liner can be fully inspected — a repair can never be done while mounted.
- Confirm repairability — Verify the injury is in the tread area and within the size limits set by USTMA/RMA, TIA, and the manufacturer; reject sidewall/shoulder injuries.
- Remove the object & drill — Remove the penetrating object and ream the injury along its angle to clean the channel.
- Prepare the inner liner — Buff and clean the inner-liner area around the injury per the repair-unit instructions, avoiding over-buffing.
- Install the combination unit — Insert a one-piece patch-plug that fills the injury channel AND seals the inner liner — a plug alone is an unacceptable repair.
- Stitch and seal — Stitch the patch down to remove air pockets and seal the buffed edges per the repair-unit instructions.
- Remount and inflate safely — Remount, lubricate, and inflate within a restraining device, never exceeding the bead-seating pressure.
- Leak-check and document — Check the repair for leaks, confirm balance, and document the repair on the order.
Quality check before you finish
- Tire dismounted and inner liner inspected.
- Injury confirmed in tread area within size limits.
- Injury reamed along its true angle.
- Combination patch-plug used (no plug-only repair).
- Patch fully stitched with no air pockets.
- No sidewall or shoulder repair attempted.
- Repair leak-checked and documented.
This is a free, source-anchored standard operating procedure (SOP) you can print and hand to staff. It documents the work sequence for a Tire Shop business — not safety or regulatory rulings, which defer to the cited authorities, the applicable code, and your own health-and-safety plan. Open the tool above to print it, toggle ink-saver, or (with a free ToolFluency Business account) edit it to match your own workflow.
Sources
- USTMA — Proper Tire Repair (Patch-Plug, Not Plug-Only) (ustires.org)
- RMA / Cooper Tire Service Bulletin #108 — Combination Repair (coopertire.com)
About Free Tire Repair SOP
Free printable tire repair SOP: dismount, inspect, and install a combination patch-plug from inside the tread area; never plug-only or sidewall repairs.
How to use
- Read the full procedure top to bottom before the work — the SOP runs in order and each step builds on the last.
- Toggle Ink-saver (black & white) for a cheaper mono print for the binder; leave it off for the full-color version.
- Click Print SOP to print or save as PDF. Print one per crew, laminate it for the binder, or attach it to the job in your scheduling system.
- Train new hires on it and have staff sign off. Found something out of date? Use the feedback link — flagged SOPs are re-researched against the source list.
Frequently asked questions
Why isn’t an outside plug-only repair acceptable?
A plug alone doesn’t seal the inner liner; industry standards require a combination patch-plug installed from inside the dismounted tire to seal the injury and the liner.
What puncture is too big to repair?
Maximum repairable puncture size and location defer to USTMA/RMA, TIA, and the tire manufacturer — oversized or sidewall/shoulder injuries are scrapped, not repaired.
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