OMC Evinrude Johnson 6 Gal tank valve stem repair

UPDATE March 19, 2021. Some of my viewers have reported problems with the Crowley's parts and recommended finding OEM parts. As of March 2021, my Crowley furnished O-Ring installed in Oct 2018 dried out allowing fuel to leak. Please search out the OEM O-ring and Quad seal.
Original note from Oct 2018. This video shows you how to trouble shoot and repair the valve stem leak at your tank's connector port. The needle valve stem seals the tank when the connector is disconnected and when pressed in allows fuel to pass from the tank through the connector into the fuel line to the engine.
These tanks were made from the early 1960's until the 1990's.

[@navand1]

Thank you for this video. Especially the info on Crowley Marine and part numbers!

[@hmongwild]

Mine is leaking same place also. I will try this. Thank you for your time to show us.

[@Mattmotors100]

I like your O Ring extraction tool. I have one too. You must be a telephone man. That tool in real life is a dial tool. It was used to remove a rotary dial to replace the phone number inside the dial. Also the tab on touch tone models to replace the phone number. The other end is used to tuck in cross connect wire. The tool is also sometimes called a spudger. It is one of my go to tools for working on outboards. works great for tucking wires in their place on mags.

[@davemilster]

I just figured out how to reply on You Tube... Sorry it has taken so long. Nope, not a telephone man. I found this tool on the ground someplace years and years ago. I'm a retired engineer/handyman.

[@kentemple6498]

Great video! I have three of these tanks. Now I know how to fix this if it goes bad. Thank you.

[@davemilster]

Be sure to use OE seals… Crowleys seals have been unreliable

[@nicholasblubaugh716]

I am having the same issue. I am wondering why you drilled a hole in the rear of the valve stem? Did you patch the hole afterwards? I bought a motor that came with two of these tanks and both appear to have this same issue. Thank you for any direction you can give

[@wish2fish37]

I ordered the same part numbers you showed and instead of getting the double lip oring they sent me a tiny oring with a very tiny inner diameter.Guess I have to get hold of them.They sent me #037858 which supposedly supercedes 0332488,but I cannot believe the little oring alone is as good as that thicker double edged one you put in?It is half as thick Or less at best.Not sure how the brass plug could be staked back in properly with the size difference?

[@anthonymarino4260]

well done

[@j.dickinson74]

Thank you for this video, I own an old tank just like yours and would like to continue using it . I have an old 2pin 1984 Mariner 8hp that I would like to use with the tank. So I need to make a hose to connect my tank to the Mariner outboard. What is the correct OMC part number at Crowley for the fuel line end plug that fits your tank? Again thanks for explaining this repair process.

[@davemilster]

Evinrude Outboard Motors 775641

[@keepitsimpleideaguy8676]

Well done, thanks!

[@davemilster]

Thanks. See my notes about finding OEM parts in lieu of Crowley’s substitution parts.

[@wish2fish37]

Thanks

[@wish2fish37]

I have one of these and if I take hose off with cap still on tank gas will come out of the fuel connection nipple from the pressure. No leaks anywhere else. You state that there should not be any fuel come out with hose disconnected. I guess I need this repair. Do these vent without connector on since it pushes other pin in?

[@davemilster]

these tanks do not vent. your valves oring seat is bad. yes you need this kit installed

[@azyxz8968]

Everybody just takes this stuff and throws it away!!!! This tank repaired is way better than a plastic tank!!!!

[@davemilster]

I had a plastic tank too and after about 8 years it was shot. This tank is from 1974 and just needed a bit of TLC and it will last another 30-40 years!

[@dickaldor]

Thank you for the video Sir! Restoring an old thank like this in the spring and wonder: It must be aluminum? Getting the list for the parts/primer/paint together and just thought I´ll ask! Dave

[@davemilster]

The tank is galvanized steel. The black pickup piece screwed to the top is aluminum. I just saw an ad on eBay for a tank like this for 34.99 in fabulous looking condition.

[@dickaldor]

@@davemilster Thank You for the reply Sir! I´ll go ahed and restore it using the right primer etc. Thank you!

[@jimvideopro]

The directions and part numbers were very helpful, thank you. However, I did the repair, and it still leaks. When fuel expands inside the tank, it's pushed out through the larger fuel feed tip, not the spring-loaded shut off. The only way to avoid it is keep the fuel line attached to the tank. The spring loaded pin does not leak. Any idea what I did wrong, and which of the two replaceable rubber parts is bad? When I was finished, the spring loaded pin was VERY tight, but I worked it back and forth a little and it loosened up. Thanks for the help.

[@davemilster]

The O-ring "inside" around 4 minutes into the video, is the seal that shuts off the fuel from leaking out the connector. If the needle isn't free to sit against this seat, then the fuel will as you mentioned leak by this O-ring into the connector. The needle should move freely in and out. I'm afraid you may need to obtain another kit, only this time slide the thicker O-ring (around 3 minutes) on the needle itself. Is it free to slide? It should be. Before putting the O-rings in, make sure the needle travels easily in and out in the housing, too. Hope this helps.

[@tripplebeards3427]

Thanks for the video. My fitting won’t seal and keeps sucking air so the motor quits. I made a cork gasket to get the fitting to fit with force over the stem so it won’t move.

[@davemilster]

Sounds like your fitting’s seal is bad. Have you tried a new fitting or a whole different hose assembly?

[@tripplebeards3427]

@@davemilster I just removed the fitting, pushed the bearing down, and cleaned the o ring. I cut the fuel line aback and inch for a better seal. I also cleaned the male fitting on the old OMC tank. I plugged it back in and got a firmer feeling primer ball. But when I wiggled the fitting gas came out between it and the tank connector. Going to start with a new fitting and see if the $4 part fixes it. The connector doesn’t fit flush for some reason. There are spring loaded rods that push against the fitting to hold it in place and also pushes it out a little maybe it’s the way it is designed and the O ring in the fitting is worn out?

[@davemilster]

@@tripplebeards3427 the fitting doesn’t usually fit flush. There will be 1/16” gap. That’s not critical as the collar in the fitting is past the holes in the male part on the tank.

[@tripplebeards3427]

@@davemilster the new fitting fixed the issue. Thanks!

[@retsof4916]

Would this connection problem cause the motor to die? I have an Evinrude fisherman 6h and my connection looks the same (loose). Thr motor runs but the squeeze ball for the gas line gets soft and I have to pump it again to restart the motor. I'm assuming air is getting in the line thru the loose connection and causing it to die?

[@davemilster]

Several things to check. 1. Is the connector on your hose an OEM OMC/Evinrude/Johnson? Aftermarket such as Atwood or Sierra may not push on sufficiently. Worse, a Chinese connector may be bad too. 2. Look at the rubber seal in the connector where it pushes onto the tank. Is it cracked? Dried out and brittle? air can get around this bad seal. 3. For another thing to try. Twist open the gas cap before you run the motor. If this keeps the bulb full then the other pin (which is the tank vent) may also need repair. There is a hole about 1/16-1/8 diameter below the vent pin. Is this hole plugged up? Take a pointed tool and scrape underneath this pin. The hole is visible between the tank and the pin. 4. Does the motor keep the primer full when on another tank? 5. Have you tried a different hose?

[@DurisM]

I have a question about this connector: do I need a special female connector (3 holes) or the regular 2 hole Johnson/Evinrude connector can do? Thanks.

[@davemilster]

This takes the regular two hole connector. Here's a link to AMAZON for the entire hose where you can see the end. www.amazon.com/Evinrude-Johnson-Compliant-Hose-Assembly/dp/B005KD93FK Several retailers make equal parts like Napa, West Marine, BassPro, Cabellas, Walmart, etc. Here's Napa's link: www.napaonline.com/en/p/BK_7511017?cid=paidsearch_shopping_dcoe_google&gclid=CjwKCAjwxqX4BRBhEiwAYtJX7doL-F7p-EsBbzDj8Q1g_e7OvatkEXil8bMJ6vmeaOBsbzIYDrWASxoC0VwQAvD_BwE

[@DurisM]

DCM thanks for that.

[@psngaming3796]

I have this problem but it's with my 1970's 9?9hp yam 4stroke on the engine's male connection the clip keeps slipping off been trying to research this issue. Probably is the O ring ...

[@davemilster]

Your Leak is around the main tube. The leak I’m showing is the plunger valve stem that permits fuel flow through the tube. Two different problems

[@davemilster]

Joshua Munoz Can a modern female fitting work on that gas tank Fitting ?

[@davemilster]

Evinrude Outboard Motors 775641

[@lumpylumpy3931]

Can someone please tell what connector I need for my OMC fuel tank

[@davemilster]

Omc Evinrude Johnson 775641

[@ChuckNorris01]

Sir, what is that 3rd prong? I'm trying to understand

[@davemilster]

the one pin with the shoulder is the latch pin. The pin with the holes is the fuel port. the small diameter pin is the shut off valve for the fuel port, so when you remove the hose connector the tank doesn’t leak.

[@ChuckNorris01]

DCM Sir, Thank you for your response. I was trying to refer to the pin on the bottom that is not inline with you had mentioned.

[@davemilster]

leeson187 the larger pin below the latch pin is a “key” pin to keep someone from putting the connector on the wrong way. The connector is narrower on the latch pin side.

[@ChuckNorris01]

DCM thanks Sir for the clarification 😁

[@jonathanbennett4804]

What fitting did you use to connect the fuel line to the fitting? What size?

[@davemilster]

I've used Attwood OMC connectors, but not been successful with them. Sierra is a decent aftermarket part. OEM (BRP OMC Evinrude Johnson) are the best. They usually are 5/16" hose size. The connectors are designed to fit these tanks. Here are three links to where you can find them (among other places). www.amazon.com/Johnson-Evinrude-OMC-Connector-Fitting/dp/B001KYNHSC?source=ps-sl-shoppingads-lpcontext&ref_=fplfs&psc=1&smid=A19A31B2DXU7GU www.boats.net/product/brp/0174507?CAGPSPN=pla&gad_source=1&gclid=CjwKCAjwjqWzBhAqEiwAQmtgT-WGX9K-1aNXMNIqxNTkvLOiTxIMMgGj7UUQkZowgsKOR3sYOF5IjRoCNoMQAvD_BwE www.marineengine.com/parts/johnson-evinrude-parts.php?year=1974&hp=25&model=25E74M&manufacturer=Johnson&section=FUEL+TANK-6+GALLON

[@tomtwhite1]

Hello. I have one of these tanks too. Mine is leaking also but from the larger pin with the holes in it. It only leaks when the can is under pressure but it will leak nonstop until the can is empty. Anyone have any suggestions, like a repair kit? Thanks in advance for your help.

[@davemilster]

The needle that was leaking on mine is also the shutoff valve to the fuel port where yours is leaking. You should be able to solve the problem doing the same procedure. As a stop gap until you have the opportunity to repair it, loosen the fuel cap part way, but not so much that the ears on the cap disengage. This will relieve pressure in the tank and should keep it from pushing the fuel out thru the port. The other option is to leave the fuel line connected at the tank (off at the engine) and assuming it has good O-Rings and seals, will also keep the fuel from leaking.

[@tomtwhite1]

Thanks. I tried lubing that little pin which did work for the most part. But it still sticks a little. Maybe the spring has worn out.

[@davemilster]

It could be the spring is broken, but more likely the O-ring INSIDE has gone bad due to ethanol in the fuel (and age of course). @@tomtwhite1

[@tomtwhite1]

DCM thanks

[@jamesrobinson8065]

Your parts lists shows quantity of 2 each. Did you actually use all of these parts? Did you disassemble the adjacent valve too? The Crowley Marine diagram indicates only 1 p/n 0332988 (quad ring) is required.

[@jamesrobinson8065]

Crowley Marine did not stock that quad seal so they sent an "equivalent" o-ring that produced enough drag on the valve stem to prevent proper shutoff of the outlet port when fuel line was disconnected from the tank. I recommend buying the original OMC quad seal (available on eBay) rather than this substitute o-ring. Here are dimensions of parts in case you want to use another source: valve seat o-ring: OD 0.350", cross section 0.07" which equates to an o-ring size 009; plug: OD 0.375", 0.064" thick aluminum; quad ring: ID 0.060", OD 0.200", height 0.108" as compared to Crowley's o-ring ID 0.036", OD 0.212", height 0.088". The valve stem diameter is 0.083". I oiled the valve stem and it seems to have reduced the drag enough so the valve works. You don't get many chances staking on the quad seal cover so again, my advise is to buy the OEM quad seal. Note that you only need quantity of one for each of these parts to fix that one valve shown in this video.

[@davemilster]

In March of 2021 I found this tank leaking fuel again, but not from the quad seal. It was the fuel cutoff. :-O As I did the video in Oct 2018 and now the O-ring failed already, I'm sorry to report that Crowley's O-Rings were subpar. The fuel cutoff was not shutting off as the O-Ring was now as hard as a rock! The quad seal was ok though. I had no success finding the OEM part unfortunately. If you find the link to where to obtain them, please SHARE the link or at least provide the website address (use DOTcom instead of .com as KZbin will strip off the address).

[@patrickprafke4894]

I'm trying to figure out how to get my connector to sit flat against the tank. It pops out about a 1/16 to 1/8th inch and doesn't seat.

[@davemilster]

Is the connector an OEM? or an after market? An aftermarket may not have the same tolerances as the OEM. Mine (an OEM by OMC) will pull back up to a 1/16"

[@patrickprafke4894]

@@davemilster yes it's an OEM one. I can't get it to close up enough to get the tank vent to work.

[@davemilster]

Patrick Prafke There is no vent on the connector on the tank. There is a fuel shutoff plunger. Will it not allow fuel to pass into the connector/hose?

[@patrickprafke4894]

It's the top and right little prong. Impress that in and the tank vents. My connector doesn't press it in far enough to vent properly. That's the issue I'm having.

[@davemilster]

@@patrickprafke4894 The top right needle is the fuel shut off which allows fuel into the hose through the large prong with holes when pushed in. This needle shuts off fuel so that when the hose/connector is removed the fuel cannot escape. In the video, at 16 seconds you can see the fuel leaking around this needle.

[@perkypat2214]

How does this tank vent?

[@davemilster]

As best as I can tell, to get the tank to vent in use, you twist the fill cap 1/4 turn. It is still held in place but is a bit free to allow air around the cap’s gasket.

[@perkypat2214]

@@davemilster I have a plastic OMC tank with a plastic cap with no breather hole. I've read some tanks "automatically vent" whether that be through the cap or the bayonet connection. I can't see how it could work through my cap. Having the cap partially opened doesn't seem a great idea, although it hasn't caused me any problems yet. I'm just trying to learn exactly how they are designed to be used. Thanks.

[@davemilster]

Perky Pat that’s all I am awAre of

[@loribauer3487]

you my as well bought a new tank

[@davemilster]

The tanks are very robust and I'm trying to help people from tossing them into the landfill. :-)

[@fishgrubblades9835]

You can't buy these tanks and the plastic ones are garbage.

[@TM1Alan]

Crowley Marine will send you a fat o ring that won't fit. They won't tell you this and when you bring it to Josephs attention he will tell you he is sending the quad ring. After a week of waiting Diego will tell you (if you ask) they don't make the quad ring anymore. These guys will ignore you hoping you'll forget you've been ripped off. I won't be dealing with Crowley Marine again. Hopefully I'll get my refund someday.

[@davemilster]

Please note that I commented in the info to skip Crowley

[@deniseandmarkfirestine7443]

Junk it buy another tank, parts cost to much to repair..,

[@davemilster]

The parts to do this repair are far less than a new tank