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F150 Broken Fuel Door Fix

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  #1  
Old 03-01-2016, 05:15 PM
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Lightbulb F150 Broken Fuel Door Fix

I guess this is a common thing and I just finished fixing mine. There are plenty of really good "How to's" on YouTube, but they don't cover the hardest part about this Fix. THE CLIPS ON THE HOUSING!!

Main PITA for me was removing the fuel door housing. There are some clips under the fender that for me where very hard if not impossible to get to. I was able to pinch the clip on the easiest one to access, applied a little pressure to the housing from under the fender to get a screwdriver in and pry open a bit, then took a old debit card and starting working up to the next clip and like MAJIC IT POPPED OUT! If I where to have seen this it would of saved me some time and a scared up arm!

Visual for removing the housing.




Did some grinding




Drilled a hole and inserted a cotter pin, to prevent the hinge from popping out again.




Hope this helps for anyone having to deal with this in the future. Ford Dealer told me the housing was broke and quoted me $200.00 to replace! I just wanted to share my experience and I added F150 in the title for others doing a "Google" search in the future.
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Old 03-02-2016, 08:00 AM
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Thanks for sharing.
It is common issue on our trucks.
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Old 03-04-2016, 10:22 PM
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Subbed. This just happened to my truck.
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Old 03-05-2016, 07:14 AM
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I had this happen to my work truck a while back.

The hardest part is getting the carrier out of the box side without scratching the heck out of the paint around the fuel door.

The rest is pretty easy. I just put it back together and didn't add the cottar pin. Mine was fine until o hit it with the pressure washer, and I haven't had any problems since.

Good write up!
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Old 03-06-2016, 06:44 PM
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Forgive me but what is the symptom that's associated with this "fix"?

My 2010 just developed a problem with the fuel door. It's won't snap closed like it used to. It hangs open about 1/2". When I open the fuel door the arm that connects to the hidden hinge is crookwards and seems loose.

Is this what this thread is about?

Thanks for any replies.

CMOS
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Old 03-07-2016, 07:28 AM
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Yep, thats it

Fix as above and you'll be golden!
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Old 03-07-2016, 11:57 AM
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Originally Posted by meborder View Post
Yep, thats it

Fix as above and you'll be golden!

Am I correct that I will not need any new parts, or will I need to replace any of the clips?

Thanks,
CMOS
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Old 03-07-2016, 02:12 PM
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Quote:
Originally Posted by CMOS View Post
Am I correct that I will not need any new parts, or will I need to replace any of the clips?

Thanks,
CMOS
CMOS, Thats correct. You shouldn't need any parts. I almost ordered a
new housing new housing
from Amazon but decided to remove mine first to see exactly what was going on. If you want to prevent it from happening again, you just need some simple tools, grinder, drill and cotter pin.

Mine clipped right back in, plus there are 3 8mm bolts that secure the housing in as well.

Keep us posted to your progress.
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Old 03-07-2016, 02:18 PM
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This happened to my 2011 F150 Lariat the first time I got gas, the door fell off the hinge!

Dealer said we cannot order it until we take a picture, send it to Ford for approval.

Ridiculous, I epoxied the damn thing back on (it's held in place by a tiny tit), then used duct tape to retain it in place.

The 2015's use a different set-up.
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Old 03-07-2016, 02:54 PM
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Quote:
Originally Posted by NumberDummy View Post
This happened to my 2011 F150 Lariat the first time I got gas, the door fell off the hinge!
This is obviously a design flaw if it occurred at your first fill-up. Mine had a good 107K on the clock before it happen to me. Nice to hear it's been redesigned and hopefully won't be a issue in the future.
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Old 03-07-2016, 05:02 PM
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Quote:
Originally Posted by NumberDummy View Post
This happened to my 2011 F150 Lariat the first time I got gas, the door fell off the hinge!

Dealer said we cannot order it until we take a picture, send it to Ford for approval.

Ridiculous, I epoxied the damn thing back on (it's held in place by a tiny tit), then used duct tape to retain it in place.

The 2015's use a different set-up.

that's a different problem where the painted cover won't stay on the inner door fixture -- easily resolved with some epoxy or even super-glue and requires no disassembly. which reminds me, I really should glue the darn thing on before I lose it. after 5 years I'm probably pushing my luck.


The fix above is for when the hinge behind the box side will no longer hold the door closed and it kinda just flops around in the wind.


I didn't have to spend any money to fix mine either. I just reassembled it the way it was and hoped for the best. so far, so good as long as I don't blast it with the pressure washer.
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Old 03-08-2016, 10:24 PM
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Had to fix the door on the 2011 Lariat I just bought. Opened the door in the dealers lot and it popped so. Used two plastic body gasket type tools to slip under the rubber and depress the clips. My back issues would not allow me to get under the bed side to work from the back.
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