2nd Generation Specific (1986-1992) 1986-1992 Discussion including performance modifications and technical support sections.

big problem (with pic)

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Old Feb 25, 2005 | 03:51 PM
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big problem (with pic)

s5 n/a
went to swap my fuel pump today and found this... all the screws are just rust, what can i do?!?!
Attached Thumbnails big problem (with pic)-fuel-pump-cover.jpg  
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Old Feb 25, 2005 | 04:01 PM
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you might have to get one of those screw extractor kits. Then buy new screws. Sorry dude dont know what else to say
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Old Feb 25, 2005 | 04:01 PM
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wd-40 and a dremel.
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Old Feb 25, 2005 | 04:03 PM
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^ ditto

Use a dremel and grind away some of the rust and then cut groove or 2 in the screw head for either a big flathead or phillips.
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Old Feb 25, 2005 | 04:03 PM
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Whatever you do, don't use a torch
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Old Feb 25, 2005 | 04:32 PM
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lol good one gene
im afraid to dremel them, they are so small i dont want to cut into the cover
i tried a phillips head on one, and it just crumbled... im afraid pb blaster will just eat them away
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Old Feb 25, 2005 | 04:43 PM
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the whole gas tank from the junk yard....
'
good luck...

Gil
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Old Feb 25, 2005 | 04:55 PM
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vise grip and WD-40 thats the same thing i did and i just twisted thos puppies out and replaced it with some nice hex bolts and washers
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Old Feb 25, 2005 | 05:00 PM
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i posted a thread just like this not too long ago. heres mine:
Attached Thumbnails big problem (with pic)-top-fuel-pump.jpg  
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Old Feb 25, 2005 | 05:10 PM
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Originally Posted by capn
vise grip and WD-40 thats the same thing i did and i just twisted thos puppies out and replaced it with some nice hex bolts and washers
ditto! same method that I used, except only half were that bad, the other half are holding it in now. Come to think of it, I probably should find the replacement screws for that...
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Old Feb 25, 2005 | 05:21 PM
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Originally Posted by capn
vise grip and WD-40 thats the same thing i did and i just twisted thos puppies out and replaced it with some nice hex bolts and washers
Exactly what I did. But I used PB-Blaster. I think the bolts I used were 6m?
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Old Feb 25, 2005 | 06:00 PM
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I was going to say drill out the screws, but im not to sure cause thats the gas tank.

If your going to do it, do it carefully. Get a drillbit that just fits into the socket of the screw. Use oil and make sure the drill (if possible) is set to a low rpm. Drill it until you think that your just at the base of the screw head. Take some pliers, and pop off the screw head. The inner threaded piece should easily spin out, improvise to get it out.

Capn, thats an awesome idea, use hex screws or allen key screws, whatever you call them. Those bastards last forever.
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Old Feb 25, 2005 | 06:25 PM
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Ran into this problem a while ago...


I just used a long cold chisel and a big hammer and whacked all the screw heads off. The thing is, there is a gap between the fuel pump cover and 'ring' that the screws go into. So there was about an 1/8" of each screw sticking up. I soaked that in penetrant and then used vice-grips to twist each one out. Piece of cake.
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Old Feb 25, 2005 | 07:09 PM
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why not go stainless steel on the replacement bolts? don't tell me you guys didn't think of that route...
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Old Feb 25, 2005 | 07:11 PM
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PB Blaster OWNZ... it's as seen on TV too.
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Old Feb 25, 2005 | 07:12 PM
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Originally Posted by capn
vise grip and WD-40 thats the same thing i did and i just twisted thos puppies out and replaced it with some nice hex bolts and washers
I agree with you!..

To make life easier replace the rusted screws with allen head screws..
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Old Feb 25, 2005 | 07:15 PM
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Soak them with PB blaster, take your dremel and cut a notch in the head to take a thicker blade straight screw driver, then use an impact screw driver to remove the screws.

You should be able to get most of them out that way.
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Old Feb 25, 2005 | 08:13 PM
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Originally Posted by Karack
why not go stainless steel on the replacement bolts? don't tell me you guys didn't think of that route...
I think a while back RETed tried to source out some SS allen wrench bolts but it never followed through. I think the price was too steep for most FC guys as usual.
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Old Feb 25, 2005 | 08:26 PM
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I have all the screws for that, they are rust free, I might still have the sending unit as well I will check monday when I get to work. if I still have it its yours, I def have the screws for sure I will send them to you if you pm me your addy.

as far as getting the old ones out, try gripping them with a pair of vice grips, I have done that before and it worked out ok as long as you can get a good bite.

brian

Last edited by driveway; Feb 25, 2005 at 08:29 PM.
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Old Feb 26, 2005 | 06:28 AM
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Originally Posted by ilike2eatricers
I think a while back RETed tried to source out some SS allen wrench bolts but it never followed through. I think the price was too steep for most FC guys as usual.
Actually, it's still in the works, and with my first paycheck in 3 years finally coming through, I'll finally get to take care of those pesky projects.

I believe there are 8 screws that hold the gas tank cover and bracket in place.
There are also 4 more than hold the check valve more toward the center of the gas tank - it's almost impossible to get to them unless you drop the entire tank.

I was thinking about doing 15 SS hex cap screws + hex key for $15.
You only need 12, but the extra 3 might come in handy.

I'll get around to ordering the fasteners and hex keys by next month, and they should pop up for sale on my website by the end of March.


-Ted
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Old Mar 2, 2005 | 06:21 AM
  #21  
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can anyone tell me what SIZE screws they are so i can replace them? i can get the screws at work today i just need to know what size (length, & #)
thanks
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Old Mar 2, 2005 | 04:02 PM
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bump god dammit
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Old Mar 2, 2005 | 04:43 PM
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Please don't use a drimmel. I don't wanna see you go up in flames. You need something a little slower and with a little less chance to heat up and spark. Use a drill on low rpms and small bit. drill a nice hole then take a torx screwdrive and cram it in the hole.....turn.
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Old Mar 2, 2005 | 05:31 PM
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Old Mar 3, 2005 | 06:39 AM
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bump again... cmon even MAZDA wont tell me
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