Fuel Cap Repair help

latvius · Feb 15, 2025

Anyone got ideas on how to reattach the chain? Or pictures of how it used to attach would help me fab something.

I thought of pop rivet also blind nut but never tried to put one in plastic. I don't want to break it since it seems like it would be hard to find a replacement.

biscuitwhistler37 · Feb 15, 2025

Hope it helps, I googled for a part number and no go, I did find marine chain and fasteners for an aftermarket marine cap, maybe they're the same size. The TM should have the part number and/or specific fastener size.

CARC686 · Feb 15, 2025

You're right to be worried about breaking your cap. You can occasionally find a used one on eBay for entirely too much money. It's cheaper to replace the entire fill hose with a civvy part.

latvius · Feb 15, 2025

Here is a better picture, yeah the TM that is not indexed, I found the PN, part is over 40YO so...
Hillbilly has em for $100 so that tells me you can't get them.

latvius · Feb 15, 2025

CARC686 said:
View attachment 940827

You're right to be worried about breaking your cap. You can occasionally find a used one on eBay for entirely too much money. It's cheaper to replace the entire fill hose with a civvy part.

That's not a bad idea using those plastic inserts

CARC686 · Feb 15, 2025

Maybe put a flat washer under the head to encourage it not to snap off the umpteenth time it goes for a swing at a gas station.

nyoffroad · Feb 17, 2025

latvius said:
Here is a better picture, yeah the TM that is not indexed, I found the PN, part is over 40YO so...
Hillbilly has em for $100 so that tells me you can't get them.

View attachment 940828

Guess who's going to dig around in the garage and sell a few gas caps?

latvius · Feb 17, 2025

Also looks like a possible 3d print project.

CARC686 · Feb 17, 2025

Y'all are seriously overthinking this. I'd have cracked my cap in half putting a blind rivet in it and replaced the whole assembly with a civilian unit by now.

biscuitwhistler37 · Feb 17, 2025

One of those body plugs from post #3 on this thread would be your best bet, the absolute fattest one you can squeeze in, believe me those plastic fins won't let go....

CARC686 · Feb 17, 2025

Just cut it short so when it breaks off, you can push it in and install another one. You can snip them to a point with a good pair of shears or wire cutters.

latvius · Feb 17, 2025

CARC686 said:
Y'all are seriously overthinking this. I'd have cracked my cap in half putting a blind rivet in it and replaced the whole assembly with a civilian unit by now.

I don't want a civy filler neck, but that answers my question about the blind nut

CARC686 · Feb 17, 2025

I don't know that it would break. I just anticipate the worst outcome and have layers of backup plans.

latvius · Feb 17, 2025

CARC686 said:
I don't know that it would break. I just anticipate the worst outcome and have layers of backup plans.

Oh I misread, but I think I will take some measurements for future reference.

Fuel Cap Repair help

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