Thank you so much for this write-up. We are on the first day of a 7500+ mile road trip when this same thing happened to us. Using your pictures and directions, we were able to fix it ourselves and continue on our trip. Thanks again!

Jen

 

Fixed it thanks to the write up. I ground down the bottom of the peg holder and heated a paperclip and rammed it through the peg. Bent the sides around so it can't come up again.

Cheers!

 

Thanks for posting this I was freaking out when this happened to me today.

 

My 2005 with a real fuel cap never has, and never will have this issue... stupid design

 

Just a quick comment ..I have had this problem happen about 10-15 times both on the oem door and the new door. I fixed it just like in the pictures but added one more step,take a soldiering iron and flip the housing upside down and mushroom out the shaft as it exits the bottom of the housing this will stop it from creeping up and allowing the door to swing freely

 

First off, thanks to the original poster for showing detailed photos of how to do this. However, I think I may have found a short cut, Keep Reading


So, maybe I am just to big, but I was unable to get my hand anywhere but to the lower right hand clip (towards the back of the truck)

So, after cutting my arm on the metal piece on the inside upper fender, I released the lower right hand clip and then started thinking.

So after thinking about it and having used credit cards to break into many a house door lock after loosing my keys, I made a decision

So I stuck an old credit card in the area of the clip that I had un done and started to work it in behind the seal and into the crack as deep as I could

Once I got up towards the top clip I just kept working it in and out with upward pressure. It was enough to pop the clip and pull the hinge assembly out.

I was lucky that my only problem was the pin popped out.
I put it back together and re assembled.

 

The same stupid jerk that designed the ford spring lock R-12 hose connector in the 80's must have designed this. I hope he reads this.

 

Just fixed mine...thanks for the write up!

 

Thank you for the clear instructions. I have 2 F150's and the workhorse is hitting the stage where things are needing an extra bit of love and attention. (Grease and maitenance). I had this done in 15 minutes after driving around for the last 3 weeks wondering how to even approach it. Thanks again.

 

Thanks for the write up. Mine sprung today & took about 10 minutes to fix. Pretty bad design it seems.

 

This is a very helpful thread!! My spring was fine. My problem was the pin that slides into the fuel door had worked its way up. After repairing the pin while the assembly was out the pin moved up again. To try and solve this problem I used some locktite and reassembled the door being careful to only get locktite on the contact points between the door and pin. Lets hope this works!!

 

Dealer wanted $250 to fix. I am glad I walked away. Great instructions.

 

I can't seem to get it out...can anyone provide pics on where the pins are to pry it out

 

They aren't really pins. If you reach your arm and hand up in there and run it around the outside of the housing, you'll feel the three places where there are small tabs on the outside of the housing. You need to use a short stubby screwdriver to depress these tabs - push them in toward the housing. If you do one and push the housing out, you'll get it started out of the fender. Then do another one and it will come right out. Once you get one pushed in you'll see how it works - it's really pretty simple once you know.

 

Thanks for the post and the pictures, good job. This worked for my F150, the fuel door flopped around too. I wound up putting a screw and washer in the bottom of the hinge post, worked like a charm.