Gas tank screw stripped

OBD · Jan 30, 2019

2005 Rancher 350 ES 4x2
My issue is the brass insert molded into the gas tank is turning so I can't remove the petcock. I was going to clean out the screen and petcock, but, there is a threaded brass fitting for the mounting screw to fit into that has come loose from the tank with the screw still tight. The threaded fitting and screw all turn together. Has anyone come up with a solution other than a new tank?

fishfiles · Jan 30, 2019

.... I been there before and just threw the tanks away , I would probably buy a tank from someone like PSN and be sure to ask if the bolts unscrew on the one I was about to purchase , but if I were in a road warrior situation , I would cut the head off the bolt with a grinder , after flushing the tank very good with water so I don't blow myself from sparks and fumes , I would then feel good to use one bolt and 3M5200 and glue the petcock down with the one bolt

Jeepwm69 · Jan 30, 2019

Put an impact on it and see if you can snap it loose, or just pull the insert out with the petcock, get it off the bolt, and then try epoxying the insert back in the tank, and go easy when reinstalling the bolt on that side.

fishfiles · Jan 30, 2019

OBD says the nut is already spinning , do you really think an impact is going to get it to turn now ............. I would have to think it is just going to make the hole where the nut was impregnated into the plastic bigger

take the other bolt out , put a pry bar under the petcock and maybe the nut will pull out of the plastic before the petcock breaks ----if that works then maybe you can grab the nut with vise grips, get it out the bolt , then try to epoxy the nut back in

Look at it this way , what could be worst than a fuel leak develop while in the woods and light the bike up in flames -----maybe you should just bite the bullet and get a new tank

Jeepwm69 · Jan 30, 2019

fishfiles said:
OBD says the nut is already spinning , do you really think an impact is going to get it to turn now ............. I would have to think it is just going to make the hole where the nut was impregnated into the plastic bigger

You'd be suprised at what a 1/2" impact necked down to a 1/4" drive 8mm socket can do. LOL.

Wouldn't surprise me if it snapped that bolt loose without moving the nutsert at all, even though it's loose.

OBD · Jan 30, 2019

Thanks y'all. I'll try Jeep's suggestion first, then try Fish's if the impact doesn't work. If it's too buggered up after prying it out, I'll look for another tank.

LedFTed · Jan 31, 2019

not to try an confuse matter's much. you might be able to JB Weld, or epoxy the brass insert, before you use the impact. its been a while since i have done this.

fishfiles · Jan 31, 2019

I need to get me one of them impacts that Jeep has , it must turn a gazillion rpms per second to be able to spin a frozen nut off of a bolt with nothing holding the nut

Jeepwm69 · Jan 31, 2019

LOL. I'm assuming that the nutsert is spinning but still has some resistance on it. If the hole is wallowed out enough to make it spin freely then I'd just undo the other bolt and pull the nutsert out where I could get it off, then try epoxying it back in.

OBD · Feb 1, 2019

Yeah, the impact wrench just spun it on out. Somewhat of a design flaw on the insert. If I was the designer, I would do it differently. But, then again, sometimes things are designed to fail eventually.

Nose Dive · Feb 1, 2019

Hay man...have you ever tried BELZONIA MOLECULAR METAL? I used it for years in refining for issues like this...

it is a 'paste' you mix up.. spread it where you need it... place the old threaded bushing or insert in place and let it dry.
it forms 'new threads' where you need them and is TOUGH AS METAL... It has a 'release' compound you can use on your
insert so it will..after drying...screw back out.. neat stuff...have used it on H2 recip compressor shafts... gas pump volutes..
lots of places...can get it off the internet... stuff is JAM UP GOOD might prevent purchase of a new gas tank.. I always have
some handy around my shop for just these 'DAG GUM IT"...to much torque issues!

God bless

Nose Dive

OBD · Feb 1, 2019

Nose Dive said:
Hay man...have you ever tried BELZONIA MOLECULAR METAL? I used it for years in refining for issues like this...
Nose Dive

Hey Nose Dive,
I was wondering what to use to try the repair. I have read that JB Weld, which is my usual go to, can break down in gasoline. Thanks, I might try it.

Jeepwm69 · Feb 1, 2019

There shouldn't be any gas in contact with the insert. Just a recess in the plastic tank where it sits.

I would use some expoxy and glue that sucker back in there, and just don't get crazy tightening the bolt back up when you reinstall the petcock.

Jeepwm69 · Feb 1, 2019

Nose Dive said:
Hay man...have you ever tried BELZONIA MOLECULAR METAL? I used it for years in refining for issues like this...

That stuff looks like it might work well to fill in wear grooves on hubs. Might have to get some and try it.

Nose Dive · Feb 1, 2019

I have used BELZONA in refinery maintenance application for over 40 years... gasoline, crude oil, diesel, weak acids and bases... water..H2 gas..sour gas..methane, propane...you name it. There are two types...one is 'machinable' the other is not... It does not break down in gasoline or oil... follow instructions... it is easy to mix and use and drys fast... good luck

Nose Dive

LedFTed · Feb 3, 2019

OBD said:
Nose Dive said:

Hay man...have you ever tried BELZONIA MOLECULAR METAL? I used it for years in refining for issues like this...
Nose Dive

Click to expand...

Hey Nose Dive,
I was wondering what to use to try the repair. I have read that JB Weld, which is my usual go to, can break down in gasoline. Thanks, I might try it.

i used J B Weld with the carb. on the 46 ford, and it hasnt broke down as yet. the last time i bought J B Weld, the black stuff was runny, it wouldnt hold anything. maybe i got a bad batch. or maybe i didnt, now they make it different?

Nose Dive · Feb 3, 2019

I have heard of JB WELD... have not used it as...BELZONIA does what...where,,,when and how I needed it to do for me...my equipment...and the equipment in refinery equipment repair situations for over 40 years.. I know...it works...and ... to date...Belzonia has NOT FAILED ME... I do not know anything about JB WELD... Sorry... God Bless guys...

Nose Dive.

fishfiles · Feb 3, 2019

Devcon is another 2 part putty that can pass the grade , I learned about it working offshore , they use it to repair 1,400 psi pipeline leaks , they mix it on the deck of the boat , the diver goes down and applies it to the leak , 20 minutes later they crank up the pressure

fishfiles · Feb 3, 2019

Jeepwm69 said:
There shouldn't be any gas in contact with the insert. Just a recess in the plastic tank where it sits.

I would use some expoxy and glue that sucker back in there, and just don't get crazy tightening the bolt back up when you reinstall the petcock.

double trouble moment ---the insert hole goes thru on a 450

you goy my wishing I would not have throw a couple of tanks away , could have tried it

Jeepwm69 · Feb 4, 2019

dang Fish. Those inserts to straight through to the tank?

One the 500 tanks if the insert comes out there's just a hollow there. It doesnt' actually go through the plastic into the tank.

Gas tank screw stripped

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