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Unread 11-07-2010, 08:26 AM   #1
UNHCLL
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Broken Oil Fill Cap?

Has anyone ever had the Oil Fill cap break?
I have a '99 4.0L.

I was in the middle of doing an oil change on Friday, only to discover the oil cap won't come off. It feels like the inner "barbs" are broken/stripped so it won't lock when trying to turn it counter-clockwise for removal. It feels normal when turning clockwise.

I anticipate it will necessitate the removal of the valve cover now to get the cap out, without leaving parts inside the valvetrain?

Filling the engine with oil again through the dipstick tube was a slow and tedious process.

Thanks,
Chris

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Unread 11-07-2010, 09:15 AM   #2
justanotherjpr
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I have had this happen once on my wife's 2002 4.0L WJ. I'm a keyboard commando for a living, but not especially weak and I could not get this thing off with my hands.

I took a screwdriver and a hammer and gently knocked the handle counter clockwise (like I was backing it out) and the cap came free. It ended up breaking in two pieces, (the upper part that has the handle, and the inner part that screws into the cover) but the inner piece screwed out with my fingers. I just snapped the handle back in and re-installed it on my XJ, and put the one from my XJ on hers.
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Unread 11-07-2010, 09:43 AM   #3
alexrule123
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That happened on both of my XJs! Just turn the cap until the top part comes of, then you can use an adjustable wrench to turn it and remove the bottom part.
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Unread 11-07-2010, 10:53 AM   #4
TDTech
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it happens all the time on the 4.0's. Bad design I guess. A new cap from the dealer is like 6-7 bucks.
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Unread 11-07-2010, 12:36 PM   #5
Spencer43783
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Yeah it's a junk 2 piece design. All of the 4.0Ls oil caps do that. The plastic on the insides get worn out and it gets stuck in there. They should have made it a 1 piece design instead of attempting the ratcheting 2 piece crap. Just pop the top of the cap off with a pair of pliers then get a big pair of pliers and grab the bottom portion of the cap and twist it off. You can snap it back together and put it back on or replace it. I grabbed one when I was at the JY so I could have a spare when mine started doing that.
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Unread 11-07-2010, 01:04 PM   #6
UNHCLL
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Thanks for the input and resolutions!
I didn't want to just start smashing on it at 6pm on Friday night.
I'll order a new cap from WorldPac tomorrow.

Thanks again!
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Unread 11-07-2010, 06:23 PM   #7
GregB_00XJ
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Funny thing...mine just did this yesterday too? I sadly had just drained out all the oil, and popped up top to pull off the cap. All it did was freewheel... couldn't tighten or loosen. FAIL

I popped the top half of the cap off with a wide flat blade screwdriver and the inside of the top was shredded. Not sure how this happened as you cant over-tighten these, but it did. Bad design I guess? I used some channel locks to get the bottom half out, finished my oil change and went to the store this morning to get a replacement.

SO lame...I have never had this happen on any vehicle.
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Unread 11-07-2010, 07:15 PM   #8
jeepkid03
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This happened once to mine but I was able to get it off. What you do is take the palm of your hand and press downward as hard as you possibly can on it while trying to turn it. Worked for me.
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Unread 11-07-2010, 09:58 PM   #9
GregB_00XJ
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Quote:
Originally Posted by jeepkid03 View Post
This happened once to mine but I was able to get it off. What you do is take the palm of your hand and press downward as hard as you possibly can on it while trying to turn it. Worked for me.
Tried that, once I got the top half off the ratchet (gears) on the inside were all mangled. It was a dead thing.
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Unread 11-07-2010, 10:13 PM   #10
99Greenmachine
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Happened to mine, I went and grabbed one from a JY...all 4.0L caps will work haha
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Unread 11-07-2010, 10:21 PM   #11
leadnbrass
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I'm on my third on (I think) the top always separates (strips) from the bottom.

I gave up and just open it with a pair of channel locks now.
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Unread 11-07-2010, 10:26 PM   #12
3vze28
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i just remember from now on not to go insanely tight with my oil cap, cause mine does it too.
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Unread 11-08-2010, 06:18 AM   #13
rugsucka
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I just use the bottom half and hand tighten it with a rubber palm glove on.

The first time it broke, after swearing a bit, I used a pair of vice grips to grab the lip and turn it open.

Until the other 30 things I need to do to my heap get done - some needed, some wanted - I will save that 5-10 bucks for something else.
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Unread 11-08-2010, 06:30 AM   #14
mikethefisher
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pipe wrench works to get it off. be sure not to make it too tight or youll crack the plastic
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Unread 11-08-2010, 07:20 AM   #15
shaman1204
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Quote:
Originally Posted by leadnbrass View Post
I'm on my third on (I think) the top always separates (strips) from the bottom.

I gave up and just open it with a pair of channel locks now.
X2. Has happened to me thrice in two months of ownership. Granted the last one was a cheapo from autozone. Channel locks work great.
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