Bummer to see this has been an ongoing issue. Stopped at the dealer today to see if they could fix mine. 2011 exactly 1 year old with 40k. No luck ... basically was told to pound sand. Hinge pin slips inside as I already took it apart to look at it. I hate the stealerships.

 

Darren---I want to say thanks for such an easy to follow write-up. Like you said, It took me less than 5mins from start to finish and I have little skills with mechanics. It was super easy. It gets me how they make such a cheap part and charge $40-$45 bucks to purchase a new one. They should have stuck with the old model. It's not like it would've weighed that much more. Again, thanks. Great write-up.

 

But then they wouldn't have to have us buy the replacement part!

No problem! I am glad it has been of use to some folks out there. My buddy had to replace the one on his flareside just recently!

 

Let me first start by saying that I have a 2010 F150 and the same thing happened. I was finished fueling, closed the fuel door and heard more of a crunch than a smooth close. The fuel door would not close (tape fixed it temporarily). I ordered part 9L3Z-9927936-B from the Ford dealer ($36 wholesale, $51 retail). I followed DarrenWS6 instructions on the removal, although not the same year. The basics were the same. Here is the major point of my post, the old part was not broken. The pin had popped out and thus was causing the spring mechanics to not function correctly. I snapped back the pin into its full correct position and it functioned fine. Since I still had a new part, and the cost was low, I installed the new part anyway. So, if your fuel door is not closing, pull it out and check it first before getting a new part.

 

Just did this replacement. It's literally a 2 cent piece of plastic that breaks (piece looked chalky and dry). If someone can figure out a way to rig up a replacement pin you won't have to buy a new housing everytime.

 

Is this How-To done on a 2005 F150? If not, can it be?

 

No my truck used here was a 2004, but it is the same exact thing. Even a flareside bed is the same procedure to replace. My friend with a flareside FX4 used this article to fix his and he said it was the same thing just differently shaped.

 

Just found this thread and I am also having the same problem with my fuel door on a 2010 f150 49,000 miles.

I just reached up and the fuel door spring fell onto my face. I posted a picture below. It looks a little different than the on in this thread but does the same thing I bet. I am going to rip out the fuel door this weekend I will keep you guys updated.

http://www.flickr.com/photos/47644917@N02/8530000188/http://www.flickr.com/photos/47644917@N02/8530000188/ by http://www.flickr.com/people/47644917@N02/, on Flickr

 

Just got the chance to fix my fuel door on a 2010 F150, good thing I didn't take it into the dealer and have them charge me for new parts and labor.

All that happen was the spring popped off its setting, I just popped it back into place and the door works good as new. Good thing, I hate billet fuel doors and I refuse to buy them.

I bet Ford is even charging customers for new parts when they don't even need them.

But now is the test to see how long it lasts.

 

My door just broke on my 05'. Your awesomely detailed repair helped me replace mine in no time and allow me to enjoy the rest of my day without the preverbial tool throwing and curse words!!!

 

I have the identical issue - there was a "snap" on the door as I was refueling and it would no longer close. I have a 2011 with 45K miles. I knew some cheap retainer clip for the spring must've broken, so I returned to the dealership for the part. Of course, you have to purchase the entire assembly as depicted in this excellent post to make the repair. Just for laughs, I had the dealership quote me the repair: $229.00!!!?? UNBELIEVABLE. The sad part is that this kind of problem shows EXACTLY what's wrong with American vehicles. Poor attention to detail, fit and finish, cheap-crap parts to save 2 cents and cut corners whenever possible.

 

I guess I should be thankful my door held up this long, but the spring or keeper is no longer working. I can tell the interior of the housing on my 2009 looks nothing like the 04-08 series, so after 30 minutes of frustration, I took a fat rubber band and fixed it to one of the screws used to support the gas tank line and wrapped it around the gas door frame and snapped the door back on to hold it in place.

It's too bad that Ford doesn't realize they have a problem with a cheap part and volunteer to fix it via a recall, but then they never did anything about the "3rd brake light" gasket above the rear cabin area leaking rain water and car wash water either did they???

Disgusted in Texas....

 

I just had my door on my fuel tank to stop closing.After getting on this forum for help it wasn't a big problem.I found the shaft had slipped up and threw the alignment off.After i pushed the shaft back down I did what bleerii77 suggested.I took a 3/32 drill and drilled a whole in the bottom of the shaft and got a number 4 sheet metal screw and a small flat washer and put in the end of the shaft and problem solved forever I hope. At least the shaft will not move out place again.Saved myself about $150.00. Thanks to all the help I recieved on this sight.

 

Just had my door break last week and I found this thread. I was able to follow this no problems and had it replaced within 30 minutes. I ended up finding the part on ebay for like $39.

I was concerned about dropping one of the bolts down the gas tank, so I covered the opening with duct tape. That's really the only thing I did differently.

Thanks again for this post!

 

Just finished replacing mine, at least I got 10 years out of it before it broke. Pin was slipping inside the hinge, tried to get it to hold in the correct position but no luck with that so I installed the new part I got on ebay for $40 and change. Sure was easy having these great directions - Thanks!!