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Well I broke it. I must have over tightened the secondary fuel filter cap last time I changed it. Anyway I was using a 1/2" drive ratchet and short extension to remove the cap and it busted out. Question. What is the best source for replacement caps and the easiest way to remove the broken cap? Just hoping if anyone else has gone through this their experience could save me some pain. Thanks
I broke mine a while back the same way. You need to use a socket on the cap instead of inserting the 1/4" drive extension into the recess... it's just not strong enough for that unfortunately. This was an expensive lesson in using the right tools, as the cap cost about $65 from my local Ford dealer. That's about your only option.
I had to remove mine using a screwdriver and hammer to slowly tap the cap counter-clockwise using the screwdriver to bite into the plastic along the circumference. It was slow, tedious work. Be careful not to get any plastic scrap into the fuel filter housing. If you do, suck it out with a vacuum bulb (turkey baster) real good before you put in the new filter. You don't want junk getting to your injectors!!!
Yes, I talked to them about the aluminum cap when I grenaded my plastic cap... but the shipping and handling charges in addition to the $45 sale price were going to be almost what the plastic cap cost me total from Ford. And I needed my cap right then; couldn't wait and couldn't fire up the truck with a split fuel filter cap.
I may order an aluminum cap from them soon, though.