My wonderful little hinge pin broke on my fuel door so it flops around. I would prefer to keep it OEM if possible. The dealer wants $55 for an unpainted one. Has anyone just replaced the pin with a nut and screw? If so, how did you fix it so the door stayed shut? I've thought about using a small cabinet style magnet to do it somehow. I know the billet ones look nice and all, but with hunting season upon me I would rather spend my money on things other than repairs. I've got it out and apart to see what was broken. How cheap.

 

I took mine completely out and couldn't fix it right. I just put a little strip of velcro on it to keep it shut and that has been working fine for over a year now. Cheap fix.

 

I hadn't thought of velcro. That's what holds my freezer door shut in my camper. It has for 5 or 6 years.

 

yah i did the velcro too ,at lest for me it doesnt shut fully ,gonna order a billet door w/hinge this weekend

 

Speaking of the fuel door? how the hell do you get it off the truck.......
do i really have to take out the 3 screws and all that black plastic for it to come out

 

Take out 3 screws and fight the black plastic out. It took me about 10 minutes to get out without scratching up the paint around it and on the door. The door was hinged way back out of my reach.

 

It's a horrible hinge design in my opinion. Pretty much all plastic, which wears out. Why Ford uses this design is beyond me. The design is way overboard and just not practical.

 

I just replaced one for a guy on a 2004. I got the hinge from the dealer without the door for $35 and you just use your original door.

Might save you a little that way?

 

You wouldn't happen to have access to the part number would you? My local dealer wasn't very helpful. They said I had to take the whole thing or nothing at all.

 

#4L3Z9927936BA

That's for a Styleside. Flareside would be different

 

I drove out the broken pin, ran a bit through the hinge holes and put in a 10-24 2 1/2 inch bolt and nut. It fits tight in the hinge and is just loose enough in the housing holes that it rotates where it won't wear out the hinge. With 2 neoprene washers for it to turn on, it feels just tight enough. I put a cabinet door magnet just on the inside of the housing to help hold it closed. Now, until the plastic door breaks off, I think it's good to go. And my wife said it couldn't be done. I think she just challenges me like that to keep me from spending money.