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Unread 06-11-2010, 10:32 PM   #1
joe002
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Fuel Filler Door Install

Saw a request for this so I figured I would post it up

I installed a Mopar Fuel Filler Door and Locking Gas Cap - including taking pictures it took one hour. Certainly not the toughest mod in the world, and it was a pretty easy install, so I hesitated to post it, but I figured I would as it may help someone out…

Before any mods:


Side view of the filler door:


You need to remove the drivers side tail light assembly to get to the filler area. You only need to remove the two inside (right) screws to disconnect the assembly:


Assembly disconnected:


Push on the connector tab to disconnect the wiring so the assembly can be completely removed:


Assembly completely removed:


Remove the old gas cap by pushing the plastic connector to the side:


You need to pop out the old filler neck. There are four tabs that hold it in place. You need to gently push on the tab with a screwdriver so it is free of the body sheet metal. This is one of the bottom tabs:


And one of the top tabs:


With the two back tabs free you can get your fingers inside the top and slide it to the rear - don’t force it or you may bend the sheet metal:


All four tabs free, slide it off:


Here’s a shot of the rear of the top. You can see the four tabs:


Here’s what it looks like with it removed:


Remove the rubber gasket from the old top:


The rounded part of the gasket is on the top (outside):


Install the old gasket in the new filler door top:


Ensure the gasket is seated properly on the front and the back:


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2008 Rubicon - 2 Door - Flame Red - Automatic - MyGIG - Power Group - Deep Tint.
AEV Pintlers, BFG KM2s 35x12.50x17, Bulldog Fab Stubby Bump, Currie F/R Adj Trac Bars, Daystar Upper Dash, FireStik FireFly antenna, Kilby Rear Shock Skids, LoD Sig Stubby Bump, Midland 75-822 CB, Mopar Filler Door & Locking Gas Cap, Rancho LCA Skids, Rancho Oil Pan Armor, Riddler Diff Covers, custom Rubi Sliders, Sylvania X-treme Headlights, TeraFlex 2.5" Spring Lift, Warn PowerPlant HD, Woods Evap Can Relo, Woods SS Relo, Yukon 5.38s
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Unread 06-11-2010, 10:33 PM   #2
joe002
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Remove the aluminum 4 mm hex key screws from the filler door:


Note that the top and bottom screws use a separate nut and they don’t have to be removed (in the picture I removed all screws):


You need to slide the two slots in the bottom of the neck into the body sheet metal, and the top two tabs are secured like the older filler neck. The picture illustrates the bottom slots:


The slots need to slide in here:


Slide the neck into position. Here’s the bottom slots in place:


Here are the top tabs clicked in place:


Ensure the rubber gasket is seated properly:


View from the tail light hole:


Push the new gas cap plastic line in the hole and screw it in place:


If you took the top and bottom screws off, you need to replace them. Here’s where the nuts will rest when they are in place:


Here’s the back of the filler door showing where they go:


Carefully screw the aluminum screws back in place. Remember that it’s easy to strip aluminum:


Align the filler door screws with the neck top. You need to screw the aluminum screws in place. Remember that aluminum screws strip easily, so don’t force anything! You should loosely start all four screws using an “X” pattern. Once all screws are started they can be tightened, again using a “X” pattern. The screws are supposed to be torqued to 15 inch pounds.


I didn’t have a torque wrench that small, so I used some Loctite on each screw:


Once the door is in place the tail light assembly should be re-installed. Re-connect the power connector and screw it back in:


Finished:
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2008 Rubicon - 2 Door - Flame Red - Automatic - MyGIG - Power Group - Deep Tint.
AEV Pintlers, BFG KM2s 35x12.50x17, Bulldog Fab Stubby Bump, Currie F/R Adj Trac Bars, Daystar Upper Dash, FireStik FireFly antenna, Kilby Rear Shock Skids, LoD Sig Stubby Bump, Midland 75-822 CB, Mopar Filler Door & Locking Gas Cap, Rancho LCA Skids, Rancho Oil Pan Armor, Riddler Diff Covers, custom Rubi Sliders, Sylvania X-treme Headlights, TeraFlex 2.5" Spring Lift, Warn PowerPlant HD, Woods Evap Can Relo, Woods SS Relo, Yukon 5.38s
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Unread 06-12-2010, 12:37 AM   #3
JLC08JK
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Thanks for the post
Learning how to install wasn't as important as seeing the value of the Mopar unit compared to the others that are available!
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Unread 06-12-2010, 06:34 AM   #4
Vin
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Thank you so much. I'll tackle this job today.
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Unread 06-12-2010, 09:11 AM   #5
Slenny
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Nice write up, been thinking of that because over the winter the lock on the gas cap freezes. Also found a new place to stash something




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Unread 06-12-2010, 09:46 AM   #6
joe002
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Thanks - it was one of my first mods, and I took lots of pictures as I thought the instructions could be a little clearer.

So far it’s held up well.

Never thought of using the space to stash something…
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2008 Rubicon - 2 Door - Flame Red - Automatic - MyGIG - Power Group - Deep Tint.
AEV Pintlers, BFG KM2s 35x12.50x17, Bulldog Fab Stubby Bump, Currie F/R Adj Trac Bars, Daystar Upper Dash, FireStik FireFly antenna, Kilby Rear Shock Skids, LoD Sig Stubby Bump, Midland 75-822 CB, Mopar Filler Door & Locking Gas Cap, Rancho LCA Skids, Rancho Oil Pan Armor, Riddler Diff Covers, custom Rubi Sliders, Sylvania X-treme Headlights, TeraFlex 2.5" Spring Lift, Warn PowerPlant HD, Woods Evap Can Relo, Woods SS Relo, Yukon 5.38s
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Unread 06-12-2010, 10:59 AM   #7
plac
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perfect dude!! got mine yesterday. thanks for the thread!

omg, that DIY is the best ive ever seen. it needs to become a sticky.
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Unread 06-12-2010, 11:23 AM   #8
1222
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What a great write-up. Well done. Those step by step instructions and photos where excellent.
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Unread 06-12-2010, 11:29 AM   #9
Rafi
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nice write up..
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Unread 06-12-2010, 11:41 AM   #10
Vin
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Easy Peezy Lemon Squeezy...


Thanks for the write up.

The only thing I did different was not take off the light completely, just letting it hang by the wires. Still had plenty of room to work.
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Unread 06-12-2010, 11:43 AM   #11
Vin
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And you're right about the screws. What a PITA to line up.
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Unread 06-12-2010, 01:02 PM   #12
Rudinater
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I would just cut the fuel line down below. Then you do have to worry about sucking gas when trying to suck on the hose.
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Unread 06-12-2010, 03:22 PM   #13
IsleSeat
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thank you very much for this excellent write up. I was actually the one who asked in a different post.
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Unread 06-12-2010, 03:28 PM   #14
plac
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I was gonna throw mine on now, but im rushed. I will wait till tomorrow when i have more time to be careful.
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Unread 06-12-2010, 06:25 PM   #15
IsleSeat
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came out great. Thanks again, Joe!
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