Intermediate 20-30 minutes

How to Replace Gas Grill Burners and Burner Tubes

Burner tubes are the most common wear item on a gas grill — corrosion, spider webs blocking ports, and heat damage all take their toll. After 3-5 years they develop holes and produce uneven flames. Replacement is straightforward, costs $20-40 for most models, and saves a service call. Here's how.

Grill Wizard — Aussie pitmaster in MinnesotaBy The Grill Wizard · Aussie pitmaster, MN

Last Updated

Recently reviewedThis how-to was last reviewed on August 9, 2026.

Tools & Materials

  • Replacement burners or burner tubes (match your model)
  • Screwdriver or wrench set
  • Wire brush
  • Pipe cleaners
  • Work gloves
  • Flashlight

Step by Step

1

Identify your burner model and order replacements

Check your grill's model number (usually on a plate inside the lid or on the frame) and search for the exact replacement. If you can't find the number, remove a burner and measure length, width, and mounting style, or take it to the hardware store. Universal burners fit many grills, but model-specific ones align better with valve orifices.

2

Disconnect gas and remove grates

Turn off and disconnect the gas supply completely. Remove cooking grates, heat plates/Flavorizer bars, and any other components above the burners. Take photos before disassembly so you remember the order everything came out in.

3

Remove the old burner

Burners are typically held by 1-2 screws or a cotter pin at the front and slide onto the gas valve at the rear. Remove the mounting hardware, lift the front, then slide the burner forward off the valve orifice. Note how it mounts — the new one goes on the same way.

4

Clean the gas valve orifice

Use a thin wire or pipe cleaner to clear debris from each gas valve opening. Spiders love nesting here — it's the #1 cause of uneven flames, and this step alone sometimes fixes uneven heating.

5

Install the new burner

Slide the new burner onto the gas valve orifice at the rear, align the front mounting holes, and secure with screws. Make sure the burner sits level. Reassemble heat plates and grates in the order you photographed.

6

Test for leaks and even flame

Reconnect gas. Apply soapy water to all connections — bubbles mean a leak. Light the burner and check for a consistent blue flame across all ports before cooking on it.

Warnings

  • Always disconnect the gas supply before any burner work. Even a small leak during disassembly is dangerous.
  • After reconnecting propane, ALWAYS do a leak test: spray soapy water on every connection and watch for bubbles.
  • Use the exact replacement burner for your model where possible. Universal burners often don't align properly with valve orifices.
  • Never modify a gas burner or enlarge port holes — this creates dangerous flame conditions.
  • If flames appear yellow or orange instead of blue after installation, the air shutter needs adjustment — the burner isn't getting enough oxygen.
  • If you smell gas at any point during or after installation, shut off the supply immediately and check all connections.

How Often?

Burners typically last 3-5 years depending on use and material — sooner if you notice uneven flames, hot/cold spots, or visible holes. Stainless steel lasts longer than aluminized steel.

Tools & Products You'll Need

Universal Gas Grill Burner Set $25

Fits most 3-4 burner gas grills

Check Price

Pipe Cleaners for Venturi $6

Clear gas valve orifices during replacement

Check Price

Common Questions

Frequently Asked Questions

How long does it take to replace gas grill burners and burner tubes?
Plan on roughly 20-30 minutes from start to finish. It's an intermediate task — some familiarity with grilling helps but isn't essential.
What tools do I need?
You'll need: Replacement burners or burner tubes (match your model); Screwdriver or wrench set; Wire brush; Pipe cleaners; Work gloves. See the full tools list above for the complete rundown.
How often should I do this?
Burners typically last 3-5 years depending on use and material — sooner if you notice uneven flames, hot/cold spots, or visible holes. Stainless steel lasts longer than aluminized steel.
What safety issues should I watch for?
The biggest things to watch: Always disconnect the gas supply before any burner work. Even a small leak during disassembly is dangerous.; After reconnecting propane, ALWAYS do a leak test: spray soapy water on every connection and watch for bubbles.; Use the exact replacement burner for your model where possible. Universal burners often don't align properly with valve orifices.. Read the full warnings section above before starting.

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