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Fuel flap hinge repair
Published by Deckchair5
29-06-2011
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Fuel flap hinge repair

If you have the locking fuel flap then they inevitably will break at the hinge, usually you are in a filling station and they embarassingly just fall onto the ground. Don't throw it away! Here's pics of how I replaced the damaged broken plastic hinge pin with a screw for a stronger job than the original

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The flap is held on by two pins, one is metal, the other plastic, no prizes to guess which one breaks

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To remove the existing hinge assembly from the car then just pull back the wheel liner enough at the bottom to gain access to the the two nuts by sliding your hand in behind the liner and remove the 2x 10mm nuts there and remove the whole flap hinge and cap assembly. NB there may be some packing washers on the threads, note now which goes where as they align the cap mount. You can leave the cap still connected but plug the filler hole if your car is on the street otherwise a passing smoker may get a surprise

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Best to detach spring for the moment to get it out of the way

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File flat remnants of the old plastic pin then choose a suitable size self tapping screw and carefully drill a small pilot hole and make sure it's going in straight. I found it best to keep drill steady and move the hinge onto it by hand with drill at VERY slow speed. Then with drill of right size so screw will grip well carefuly drill to actual size you want and slightly deeper than the screw depth

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Screw the screw in to cut the thread and make sure it threads in straight

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Now reassemble everything and remember you want the screw tight in the thread but not tight on the hinge as it is a hinge. Reattach the spring and reinstall

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And, of course, because it's the existing flap then no spraying to do for a perfect match

Cost 2p screw and 30mins labour. Fixes don't get much cheaper than that (otherwise parts would be 30 plus cost of respray )
Thanks Bates, Maggott, Yellow Peril thanked for this post
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Old 29-06-2011   #1
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Re: Fuel flap hinge repair

Thanks Decks, great guide. Mine broke in a different way - one of the plastic tabs that holds the pins on the flap itself snapped off. Still repairable though. Took it to a body shop who glued the tab back on to the flap with some special epoxy.

Good tip is to keep the hinge mechanism well lubricated to avoid breakage in the first place!
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Old 29-06-2011   #2
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Re: Fuel flap hinge repair

Hi Phil
I knew it was a weak spot so I took especial care of it all the way through and often lubed the hinge and very carefully opened it each time but the hinge pin is plastic and so small that it's only a matter a time before they break. You can see the broken pin in the 2nd photo. I made it to 90,000miles so that's not so bad
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Old 22-03-2012   #3
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Re: Fuel flap hinge repair

Thanks a million for this informative post. My fuel flap fell off exactly as you describe in your intro. (spooky no?) Followed your instructions to the letter, and viola!!
good as new... thank you again.
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Old 21-04-2012   #4
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Re: Fuel flap hinge repair

Thanks for this top tip, my wife just filled up with fuel and drove home without noticing it hanging off! Now fixed and lubricated.
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Old 30-04-2012   #5
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Re: Fuel flap hinge repair

In mine the thing on the red circle broke. Four layers of 2 component epoxy glue and 24 hour later and it's good as new. But it needs A LOT of glue...

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Old 09-05-2013   #6
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Re: Fuel flap hinge repair

Hi guys! in my case, I've purchased a similar fuel flap from Ebay and I want to replace it rather than just the hinge, trouble is I can't access the screws to remove the existing flap, I'm not quite sure what the Wheel liner is, Does it mean I have to remove the tire? thanks for your response in advance.
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Last edited by pdania; 09-05-2013 at 12:50.
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