Well, I got the Roush billet fuel door today and went out to put it on. Should have been the simplest install in the world. I used a flathead screwdriver to push the tab in on the "hinge" to remove the stock door, and it split off. I was being very gentle, but it just gave way. I think the cold temps here made the plastic brittle? So now there is no tab to retain the fuel door. I tried fixing it with a 2 part epoxy, no dice. So I figured I'd run by the dealer tomorrow and see if they have a replacement part. You can't remove just the plastic hinge that the door attaches to from what I can see, you need to remove the 3 small bolts holding the whole plastic assembly to the filler neck. I removed the 3 bolts, but there seems to be no way to remove the plastic assembly even once the bolts are off. You can't pull it out toward you because the hinge is recessed on the left by about an inch and a half. And I don't believe you can push it through because it sits on a lip. I'm having a tough time here, all on a job that shoulda been 5 minutes, if that. Has anyone else had this problem before? Is there a way to remove that assembly easily that I'm just not seeing? Thanks.
Ryan

 

post up some pics of what you got

 

pics dude

 

I'll try to put some up tomorrow. It's pitch black out here now, they wouldn't come out very well. I'm gonna stop by the Ford dealer in Londonderry, NH to see if they have the replacement part. I can't believe the tab just broke so easily. I tried a two part epoxy to put it back, but it wasn't in exactly the right place to lock in the new fuel door, and for whatever dumb reason the epoxy never set. it's a 50/50 mix, and it was mixed just fine, never had this trouble before! Now I'm driving around without a fuel door and I hate it!!! Agggg!

 

Still no pics, sorry, but I will put some up as soon as I can. I went to the dealer and they showed me the replacement. It's not the whole plastic cup that sits around the fuel neck, the replacement is the fuel door arm and fuel door. Somehow you are supposed to be able to take of the little "spring" clip that helps the door stay closed, then pull a pin and pull the whole arm right out. So I ordered the part, it's $40 for the fuel door and arm. you can't get just the arm for whatever reason, even though the door just clips on. I just need to figure out now how to get the arm off. I will post pics of the process once I get the replacement part. I can't be the only one ever to bust the little retaining tab!!!