Wrangler Gas Cap & Bezel Mod

SkyjacktZJ · 08-02-2005, 05:26 AM

I seem to remember some discussion on this mod and maybe even a write up some time ago by others that have done this (maybe even another forum?). It's where you remove the stock fuel door and replace it with the plastic bezel that comes standard on the Wrangler models ('97-'2000). As I recall there was something that had to be modified to use the stock ZJ's gas cap and having to remove an interior panel to get to the screws that hold the door hinge on. My Haynes manual didn't have anything on the door removal at all. I searched the crud out of it and cannot seem to find it anywhere.
Anyone remember this mod or can point me to a thread somewhere?

Thanks in advance

**ChicagoGuy** · 08-02-2005, 11:10 AM

If no one replies, I'll do it this weekend and post pics.

Near as I can tell, you need to remove the fuel filler door, which is bolted to the body behind the interior panel where the spare tire goes, pop the remote release cable housing, and trim the bottom to fit the different angle.

SkyjacktZJ · 08-02-2005, 11:50 AM

Quote:

Originally Posted by VetteDriver

If no one replies, I'll do it this weekend and post pics.

Talk about "stepping up to the plate..."

Thanks, Vettedriver

**Buddha_Kip** · 08-02-2005, 01:47 PM

Swamp boy did the mod to his ZJ. I don't know what all he had to refab, but if you want to pm him, I'm sure he'll give you the 411.

SkyjacktZJ · 08-02-2005, 04:32 PM

Thanks. Here's the link:
http://www.nagca.com/forum/viewtopic.php?t=11798&highlight=door

ZJunk · 08-02-2005, 05:43 PM

i want to do this too!

SkyjacktZJ · 08-02-2005, 07:09 PM

The holes around the gas filler neck on the Wrangler bezel do not line up with the four holes on my ZJ. The holes on the bezel are symmetrical to the filler neck. The holes on my ZJ are offset to the filler neck.

The part I got is for a 1997-2000 Wrangler.

What gives?

EDIT: I checked Swamp Boy's info and found this link:
http://jeephorizons.com/phpbb/viewtopic.php?p=39286#39286

I think I'm probably going to do what Cool94gc did, but drill all 4 holes through the bezels holes & use self tapping screws. Just got to figure how much to trim out of the filler neck hole to get everything to look "factory".

**Texas ZJ1** · 08-02-2005, 10:04 PM

Why?

Hunter

Swamp Boy · 08-03-2005, 03:10 AM

Cool94 said he didnt want to drill any holes in his body...

It didnt really matter on mine..

Whats a few more holes..

I actually have a writeup from the install somewhere but I cant find it myself...

Nice find on the original thread where I asked how Risko did his..

Searched as far as Fri Dec 26, 2003 Thats awesome..

SkyjacktZJ · 08-03-2005, 05:51 AM

Quote:

Originally Posted by Texas ZJ1

Why?

Hunter

Simple: 'cause I like the look.... for now

+ I get bored easily

SkyjacktZJ · 08-03-2005, 02:31 PM

Swamp Boy

Did the TJ gas cap fit OK? I was worried about sealing enough so as not to throw any error codes.

Thanks

Swamp Boy · 08-03-2005, 04:47 PM

Been on well over a year ...No problem.... Dont worry about the seal.. It will be fine once you get the surround to fit..

**ChicagoGuy** · 08-07-2005, 10:18 PM

As promised...the install.

It did NOT go as expected, but maybe my purpose in life is to serve as a warning to others!

Disassembly is super easy. First thing to do is pull the two rubber stoppers and the cable latch. The cable latch comes out if you compress the sides. The stoppers just pull right out. In the picture, I've already pulled the bottom one.

Next thing to do is pull out the trim panel behind the spare tire (or nitrous bottle in my case!

) and unscrew the two 10mm bolts that hold on the filler door. A word of warning. I dropped one of the bolts into the body panel gap and couldn't find it. It rattles now when I drive...it's annoying.

BTW, on the back of the bezel is a small nub that probably aligns the fit on a TJ. On a ZJ, it just gets in the way. Cut it off.

Once that was fixed, I test fitted the bezel. The circumference is right on, but the angle of the TJ base is apparently about 15% less than the ZJ.

Now it's time to trim out the center piece. At first, I just tried to file it down a bit. Didn't help. Then I started to cut small sections out. And cut. And cut some more. Then I took a break, pounded a Red Bull, and cut and cut and cut and cut...

Crap! At this point, I should confess...I suck at this kind of thing. Give me a chainsaw and I'll clear the field in record time, but ask me to trim up a garden, and I'll hack it to pieces.

Part two to follow.

**ChicagoGuy** · 08-07-2005, 10:20 PM

Hey, it wouldn't be a home install without some blood, right?

I had detached the filler neck and thought about using shims, but honestly at this point I didn't care anymore, and figured I'd be buying another bezel anyway, so went ahead and cut out ALL of the center.

Hey, at least it fit. Of course, now you could see the white paint from inside the door. So I took the easy way out and sprayed it with black spray paint.

Then I marked the bezel up a bit (it fit better if slightly turned). and drilled four holes.

And it was done. It passes the ten foot test for now, and when I get a chance I'll order a new bezel and get the Wrangler cap as well.

If anyone with talent (Swamp Boy?) has a picture of the template/cut they used, it would be appreciated. But at least now there are some pictures in the thread for reference!.

HTH

**EMTimZJ** · 08-07-2005, 10:58 PM

Hey that looks nice!

Quote:

Originally Posted by VetteDriver

...I dropped one of the bolts into the body panel gap and couldn't find it. It rattles now when I drive...it's annoying...

Why does it seem that there is some cruel law of nature that every home project involves fumbling some object that gets lodged into some void that is nearly impossible to retrieve?

Maybe try one of those flexible magnetic sticks

Or if you can get to it from the other side (on the bottom) just stick a junked speaker magnet to it to keep it from rattling

08-02-2005, 05:43 PM	#6
ZJunk Registered User Join Date: Jan 2005 Location: Austin, TX Posts: 66 Profile Gallery Classifieds My Jeeps	i want to do this too!