How to Replace Gas Grill Burner Tubes
Burner tubes are the most common wear item on a gas grill. After 3-5 years, they corrode, develop holes, and produce uneven flames. Replacing them restores your grill to like-new performance and costs $20-40 for most models.
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Tools & Materials
- Replacement burner tubes (match your grill model)
- Screwdriver (Phillips or flat)
- Wire brush
- Pipe cleaners
- Work gloves
Step by Step
Identify your burner type and order replacements
Remove a burner and bring it to the hardware store, or measure length, width, and mounting style. Search your grill's model number online — most manufacturers list replacement parts. Universal burners fit many grills but model-specific ones are ideal.
Disconnect propane and remove grates
Disconnect the propane tank completely. Remove cooking grates, heat plates/Flavorizer bars, and any other components above the burners. Take photos before disassembly so you remember the order.
Remove the old burners
Most burners are held by 1-2 screws or a cotter pin at the front and slide onto the gas valve at the rear. Remove the screws, lift the front, and slide the burner off the valve. Note how it mounts — the new one goes on the same way.
Clean the gas valve orifices
With the burners out, use a pipe cleaner to clear each gas valve orifice. Debris, grease, and spider webs accumulate here and restrict gas flow. This step alone can fix uneven heating.
Install new burners and reassemble
Slide the new burner onto the gas valve, align the front mount, and secure with screws. Reassemble heat plates and grates. Reconnect propane, do a leak test (soapy water on connections — bubbles mean a leak), and do a test fire.
Warnings
- Always disconnect propane before any burner work. Even a small gas leak during disassembly is dangerous.
- After reconnecting propane, ALWAYS do a leak test: spray soapy water on every connection and watch for bubbles.
- If flames appear yellow or orange instead of blue after installation, the air shutter needs adjustment — the burner isn't getting enough oxygen.
How Often?
Replace burner tubes every 3-5 years, or sooner if you notice uneven flames, hot/cold spots, or visible holes in the tubes.
Tools & Products You'll Need
Universal Gas Grill Burner Set $25
Fits most 3-4 burner gas grills
Pipe Cleaners for Venturi $6
Clear gas valve orifices during replacement
Common Questions
Frequently Asked Questions
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What tools do I need?
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