Not sure on the plastic cap, but to get the brass cap back on you need to use a C-clamp to compress it. I tried it they way you are describing and only managed to cut my new o-ring.

 

 

Well, if no one else chimes in, I've got a couple regulators on the shelf at home that I can take apart and check.

 

I busted one of mine open and here's what I found...

 

Looks like yours is there but maybe missing a piece. Mine just slid out; it looks like a screw but it's not.

 

It's all one piece, right? Looks like the top broke off the OP's part.

 

Yes, it's one piece. OP does appear to be missing the top part. Not sure if it will make any difference or not.

 

Interesting, when I took mine apart it had that black spiral piece, but it seems as though the top flat part that looks like the cap is just missing from it. Interesting, I wonder how that would have happened. I didn’t see it when taken apart, so 99% sure it did t fall out when I opened it. Guess i will put it all back together and see how it works out. Thanks a ton for taking yours apart and taking a look at it, much appreciated.

 

So it seems i have another problem, which I can only guess is related to the FPR. I put it back in and have been driving the truck the last two days perfectly fine. I fired it up this afternoon just as normal, little smoky while warming and potent exhaust, makes the eyes burn some, but same as always. It was sitting in the driveway for a few minutes warming up while I was gathering stuff etc. and then suddenly died. Tried to fire it up again and nothing. after a few more attempts it would occasionally try and start to fire, but then die. If holding the throttle down, a couple times it fired and revved up, but then died. If not holding the pedal down it would just crank, but not fire, maybe give a cough like it wanted to fire but nothing.

Now just sitting in the driveway blocking the garage and cant get to start:/. Anyone have any thoughts on what it could be or what to check?

 

Always possible the FPR plunger is sticking, or you didn't get the spring on the nipple on the back side of the FPR nut and it popped loose and its building no fuel pressure because it finally popped loose.

 

 

Mine did that when somebody poured sand in my gas tank.

Every now and then a piece of silica got passed the screen and would freeze up my FPR.

I didn't know any of this at the time and figured my fuel pump went bad.
Took everything apart and replaced the pump, went to put the bowl back on and it was full of silica. was like. "oh that explains everything"

 

Well I don't know about the stock system, but with efuel my truck will run and drive (with serious lack of power) WITHOUT any fuel pressure and no power to the fuel pump. So I have a hard time believing that a bad spring in the regulator is causing it to not start.