This sounds like my problem. When I looked closer after taking the tip off, I noticed that bead in the center of the pic. Hope you all can see what I am talking about from the pic. I assume that is not supposed to be there. I tried pulling it out with needle nose pliers, but no luck. See what else I can do. If no luck tonight I will take it in. I would like to add gas to the welder, but went cheap because of all the money spent on my 40 so far.
Rudy
Rudy, try carefully dissambling the gun. Usually can unthread the socket assembly that the tip screws into. This will expose 1/2" to an 1" of the sheath. Carefully cut the end of the sheath off with a die grinder or a dremel. Less is more here! reassemble and test. it will likely work like new! The sheath will, over a short time, elongate. The important thing is to ensure the tip is in full engagement with the sheath or "K'pow!" welded wire/sheath.
Good luck