Step-by-Step Guide: How to Fix a Flat Tyre with a Repair Kit
A flat tyre does not have to mean a tow truck. With a tyre repair kit and a portable air compressor, you can fix a puncture and get back on the road in under 15 minutes. This guide shows you exactly how to use a tyre repair kit step by step, from finding the leak to inflating the repaired tyre.
Hearing the thumping sound of a flat tyre is a sinking feeling. But if you have a Boost N' Inflate unit in your boot, you have a secret weapon.
Included with the unit is a tyre repair kit that can seal a puncture and get you back on the road in under 15 minutes — often without even taking the wheel off the car. Here is exactly how to do it.
Safety First: When to Attempt a Tyre Repair
Only attempt this repair if you are in a safe location away from traffic. If you are on a highway, do not attempt repairs — call for help instead.
Read our breakdown safety guide to understand when it is safe to perform repairs versus when you should wait for assistance.
What You Need to Repair a Flat Tyre
Before you start, gather these tools from your tyre repair kit:
Pliers for removing the nail or screw. Reamer tool (T-handle with rough spiral shaft) for preparing the hole. Insertion tool for pushing in the plug. Rubber repair plugs (sticky rope-style). Air compressor or tyre inflator. Knife or side cutters for trimming.
Before starting, make sure you understand the legal requirements for tyre repairs in Australia — specifically which types of punctures can be safely repaired and which require professional attention.
How to Use a Tyre Repair Kit: Step-by-Step Guide
Follow these eight steps to repair a punctured tyre using a plug-style repair kit.
Step 1: Locate the Leak
Inflate the tyre slightly using the compressor to help find the hole. Listen for hissing air escaping. Look for a nail head or screw embedded in the tread.
If you cannot find the leak, pour water over the tread — bubbles will show you exactly where the hole is.
Step 2: Remove the Object
Use pliers to grip the nail or screw firmly and pull it straight out. Air will rush out but this is normal. Keep the object to show your tyre professional later.
Step 3: Ream the Hole
Use the reamer tool (the T-handle with a rough spiral shaft). Push it into the puncture hole. Move it up and down and twist it several times to prepare the rubber surface.
You are not damaging the tyre — roughening the edges helps the plug bond properly to create a lasting seal.
Step 4: Load the Plug
Thread one sticky rubber plug through the eye of the insertion tool until it is halfway through — like threading a large needle. The plug should be centred with equal amounts on each side.
Step 5: Insert the Plug
Push the insertion tool firmly into the hole. This requires strength. Push until about 10 to 15 millimetres of the plug remains sticking out of the tyre surface.
Important: Do not push the plug all the way inside the tyre.
Step 6: Seal the Repair
Pull the insertion tool straight out in one smooth motion. The plug will stay inside the tyre, forming an airtight seal. The sticky rubber bonds immediately to the prepared hole.
Step 7: Trim and Inflate
Trim the excess plug material flush with the tyre tread using a knife or side cutters.
Then inflate the tyre back to the correct PSI using your Boost N' Inflate or portable compressor. Your tyre placard (usually on the driver's door frame) shows the correct pressure for your vehicle.
Need help with tyre pressure? Read our guide on optimal tyre pressure for safety and fuel efficiency.
Step 8: Final Check
Pour a little water over the repair area. If you see no bubbles, the seal is good and the tyre is safe to drive on. If bubbles appear, you may need to repeat the process with a second plug.
Watch our quick video tutorial
What Happens After a Tyre Plug Repair
Congratulations — you have just saved yourself a tow truck wait and a potential $200+ call-out fee. You handled a roadside emergency like a pro.
This repair is temporary — designed to get you safely to a tyre professional. Once there, they can inspect the tyre from the inside and apply a permanent mushroom-style patch if the tyre is still safe to use.
Drive carefully and head to a tyre shop to have the repair inspected within 24 hours.
Get the Complete Tyre Repair Kit
The Roadside Rescue Kit includes the Boost N' Inflate with integrated air compressor plus a complete tyre repair kit — everything you need for emergency puncture repairs in one package.
If you already have a Boost N' Inflate, you can purchase the Tyre Repair Kit separately.
Prepare for Any Roadside Emergency
Make sure you have all the essential tools in your boot so you are prepared for any roadside emergency.
Our roadside emergency kit checklist covers everything Australian drivers should carry.
Understanding how tyre condition affects stopping distances will also help you appreciate why proper tyre maintenance matters.
For more detailed information on tyre repair kits, read our complete guide: Tyre Repair Kits Explained: Types, Tools and How to Use Them.
Frequently Asked Questions About Tyre Repair Kits
How long does a tyre plug repair last?
A properly installed tyre plug can last the remaining life of the tyre. However, Australian tyre professionals recommend having a permanent internal patch applied within a few days. The plug is designed as an emergency repair to get you to a tyre shop safely.
Can you repair a tyre sidewall with a plug kit?
No. Sidewall damage cannot be safely repaired with a plug kit. Tyre plugs are only suitable for punctures in the tread area. If the puncture is on the sidewall or shoulder of the tyre, you need a replacement tyre.
Is it legal to drive on a plugged tyre in Australia?
Yes, it is legal to drive on a plugged tyre in Australia as a temporary repair. However, the puncture must be in the tread area and the repair should be inspected by a professional. Read our full guide on tyre repair kit legality in Australia.
How many times can you plug the same tyre?
A tyre can have multiple plug repairs if they are spaced apart and all in the tread area. However, if two punctures are close together or the tyre has several repairs, replacement is safer. Consult a tyre professional for advice on your specific situation.
Do you need to remove the wheel to use a tyre repair kit?
No. One of the biggest advantages of a plug-style tyre repair kit is that you can repair the puncture with the wheel still on the car. This makes roadside repairs much faster and easier.