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Resealing older Newton fuel caps (pt. 1)

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AN23

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We recently started seeing fuel leaking out of our locking Newton fuel caps when the tanks were full or, sometimes, when doing acro. Our RV-8 is a 2004 and we acquired it last year. It was built with the optional locking caps that were offered at that time. This is what they look like. I called Van's and they could offer no help but they did mention that ACS had some parts that may work. I contacted ACS and found that they had a Newton A20L reseal kit so I ordered two. When they arrived, they didn't appear to be the correct parts so I sent them back. A short time later, I sent an email to Newton asking for any available help and Robin Voice, the owner, got right back in touch with me (amazing customer support). I had to send Robin a photo as he told me there were actually three variations of his design sold but they were all called the same thing! Robin also told me that the ACS parts should work but the new red end cap is now a one-time only part and that you can reuse the old pin style or use the new clip type. So, I reordered the ACS parts and they arrived yesterday. Part two will show and describe the disassembly, reseal and reassembly.
 

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Resealing older Newton locking fuel caps (part 2)

So, the first step is to mark reference points on the various parts so that you can be sure and get it back together correctly. Next, turn the key to the locked position which will allow room for the pin to be removed. (Leave the key in the lock as it will retract and retain the tumblers when you disassemble the unit). The pin is a grooved pin that is simply pushed out of the shaft. Mine wouldn't budge initially but a squirt of Kroil on each end allowed me to push it out using an appropriately sized punch. BTW, the grooved area on the pin is not centered so push it toward the short end of the pin. There is a spring located under the red cap but it just applies a little upward force. Stuff won't try to jump out at you. You can then remove the red cap, the spring and the white rotating cam (note the way the orientation of the cams and posts on the underside of the rotating cam. Next. Remove the metal insert. The large, cap to tank sealing o ring will now be exposed and can be removed to be replaced with a new one from the kit.

Continued in part 3
 

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Resealing older Newton locking cap (part 3)

Next, if you look on the very end of the lock tumbler, there's a shoulder and another small o'ring. Replace that o ring with one from the kit. Lastly, the plastic housing that contains the lock cylinder needs to be gently pushed out of the surrounding metal housing. This will expose the last o ring which sits in a groove on the inside of the metal housing. Reassembly is just the reverse but be careful reseating the black plastic lock cylinder housing back into the metal housing. It's very easy to cut that very small (cross section) o ring located in the groove of the metal housing. Just gently rock it a little from side to side all around until it seats. The lock should be flush with the face. The new, large tank sealing o ring goes on, then the metal plate and then the white cam assembly and finally the spring. Now, you have a choice. You can either use the original red cap and pin or the one-time only cap that is supplied with the kit. I chose to reuse the original cap and pin as I just like the security of the locking pin. The pin is a little tricky to get lined up and reinserted but it's completely doable.

Special thanks to Robin Voice with Newton. He's spent a lot of his valuable time supporting a 16 year old cap.
 

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