I have an E99 that has the fuel filter cap with the large nut molded on the top.
I try to remove the cap with no luck. The cap is on so tight that the nut on top will no longer hold the socket. It's now stripped. Since 2005, I have never seen a cap this tight.
I'm thinking of draining the fuel bowl and taking the die grinder with a cutting wheel to cut out sections and carefully remove the cap. I have a new fuel filter and new style cap uses the fuel filter wrench. Anyone have any other ideas?

Thanks and Happy Easter!

Jeff

 

Use an oil filter wrench on the outside edge of the lid and ignore the nut in the center.

 

My stocker has the webbing or spoke looking cap,does yours, or is it smooth? I use the ends of the handles of a pair of channel locks in the recesses to turn it. Also to lock and unlock my hubs as I can't get my hand in the hub cover on a dually.
Jim.

 

Heat it up?

 

You can use a strap-wrench or if yours has the raised bosses along the edge of the top, a piece of 1"x 1" lumber about 16" long. You just kind of bump it with the palm of your hand.

 

Might help to open the drain valve, and release the pressure first.

 

I've used something with two blunt ends and a rubber mallet on mine when I've had to. Works like a charm. I had the aftermarket replacement caps though.

 

Just did mine (aftermarket nut top) a couple days ago, but the torque was correct, 29 ft-lbs I believe since I was replacing one I'd previously done. I always use a 6 point 1" socket on that thing bc I'm terrified of stripping the plastic bolt head. You weren't using pliers were you?

First one from the previous owner was welded on there, speaking figuratively of course, and I had the same problem as you. What I did was drill two holes about 4" apart in a piece of small angle stock, about 1" legs, and use that as a template to drill two holes in the top of the filter cap. Then, insert two bolts in the holes, about 2" overall length for each bolt, that will fit in the holes (1/4" or 5/16" bolts, use something a little beefy). Tighten with a nut on the underside. You've now made a kind of homemade spanner wrench. insert the bolts into the holes and turn. The tighter the fit the better on the bolts/holes. The bolts didn't really thread into the plastic on the top of the filter cap since it's plastic but I suppose you could do that, too.

PM me if you want and we can hook up on the tellie and I'll explain in more detail. I wish I had taken some pictures now, but that was before I discovered FTE.

Hope that works for you, took a little prep time but spun that filter right off and you didn't have to worry about nicking your fuel bowl with a grinder. Overall, I think this also would take less time depending on what you had on hand. You could weld some studs to a piece of rebar, etc. There's lots of ways to achieve the same thing.

 

Did as suggested. The cap wouldn't budge. Ended up taking the die grinder and cutting the cap then prying out the small side, tapped the other side to come off. It worked and no damage to the fuel bowl housing. Installed the new filter and used a little white grease to the threads of the new cap and installed.
Test and no leaks found......Thanks for your help.

Jeff

 

Done that first. I guess I should have stated it in my original post.

Jeff