davidpFX4

My 05 fx4 has had a floppy fuel door for a while now. I finally decided to try and fix it last weekend but I can't get the damn thing out. YouTube has a few fix videos but they're all based on 09+ models and none of them really show how to get it out.

I know this is a a relatively common problem so I'm hoping somebody here has some insight.

Thanks! !

nrivera04

Take the screws out and it pretty much snaps out. There's 2 tabs up top that you need to break off to help get it out. I say break off cause you're not gonna be reusing it... Be careful not to mess up the fuel door as you have to reuse it on the new assembly.

nrivera04

Bernie963

When I bought my 05 last July I noticed a piece of soft Velcro holding the gas cap shut. By later in the summer it was loose and I decided a quick fix was in order. After reading about replacing the housing I came up with my fix. I took a piece of light canvas and folded it to the right thickness and then super glued it to the plastic housing. It works like a champ. Friction holds it tight. Attached is a picture of the repair. So far, so good....

bernie

davidpFX4

Thanks guys. I took the screws out and was trying to pop it out from behind, didn't see those tabs on top.
I'll give it another try when it not in the single digits outside.

purplepickup

a magnet a washer and some JB Weld will fix the problem far cheaper and faster than taking it apart.

60DRB

Magnet trick is kind of clever!

There are videos that show about 85% necessary info, but replacing the assembly really isn't difficult. Just take your time. Replaced mine last month. I loosened the fuel fill tube anchor on the frame to make it go back together easier.

purplepickup

Go to Home depot / Lowe's get a cabinet lock. Drill an appropriate sized hole in the fuel door. Install the lock, mark the inside where the lock hits and, using a dremel or other appropriate tool cut a slot for the latch. Now you have solved 2 issues;
1. Fuel door stays shut
2. No one can access your tank to siphon your gas.

Just remember to put the keys on your keyring.