Gbruno said:
When I was filling the tank about a month ago, I must have overfilled it. Heard a big pop. I think the tank expanded and the fuel sender began leaking. When I pulled out the screws they felt wrong (cross threaded?). Sure enough three of the five new screws dont fit well into the exisitng screw holes. Tried other screws but none worked. I could screw them in half way but then felt the resistance. I think the 3 screw holes got ruined (streched) when the tank popped. Im keeping the tank filled about 3/4 an the new sender is not leaking, but I need to address this. Any suggesstions appreciated.
You couldn't have overfilled the tank. I don't know what the popping was but that doesn't sound good to me.
Some thing shifted, I suspect. The sender screw hols also would not have stretched.
Most likely when removing the screws, you stripped the holes. You can drill for bigger scresw but you will also have to tap the holes.
If the new screws or existing screws are too long, they will bottom and you might feel that resistance you described.