I don't think that it's due to crooked replacement of cap. I have that problem on a Craftsman, and I think the plastic tank got slightly distorted.
It sounds like the thread on the cap is damaged due to crooked replacement of cap. Try putting the cap on correctly and screw on very carefully. You may be lucky that the thread is not too badly damaged.
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we are having the same problem with the cap! it doesnt want to fit correctly
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