Fuel Door Installation
My first mod. MOPAR fuel Door.
All I can say is,, what a pain. You would think something from MOPAR made for one of there vehicles would fit better. The install is straight forward but it ends there. Getting the old housing off was not to bad, but putting the new housing in for the fuel door was a bear. The two lower clips went on ok. There was no way the upper push clips were going to seat right. I had around a 1/16th of an inch of the upper clips what would not push behind the sheet metal. And this is with the housing’s collar pushed flat to the sheet metal.
To make a long story short I used my grinding tool and I took off around a 1/16th of an inch from the upper push tabs on the housing. Well look at this it fits ,,Hurray, And only after 1.5hrs off getting pissed. I still have a very small gap between the housing and the sheet metal, the thickness of a piece of paper but it’s tight. I’ll wait for some warmer weather and put a small bead of RTV around the top of the housing ware the gap is. No dig deal.
All I can say is,, what a pain. You would think something from MOPAR made for one of there vehicles would fit better. The install is straight forward but it ends there. Getting the old housing off was not to bad, but putting the new housing in for the fuel door was a bear. The two lower clips went on ok. There was no way the upper push clips were going to seat right. I had around a 1/16th of an inch of the upper clips what would not push behind the sheet metal. And this is with the housing’s collar pushed flat to the sheet metal.
To make a long story short I used my grinding tool and I took off around a 1/16th of an inch from the upper push tabs on the housing. Well look at this it fits ,,Hurray, And only after 1.5hrs off getting pissed. I still have a very small gap between the housing and the sheet metal, the thickness of a piece of paper but it’s tight. I’ll wait for some warmer weather and put a small bead of RTV around the top of the housing ware the gap is. No dig deal.
I just bought a 2010 Unlimited Sahara, and was trying to install the mopar black fuel door the other day. I can't seem to get the old mounting off. I was able to get the two visible clips pressed and past the metal, but could not "work" the hidden clip(s) out. Any ideas as to how I might try this again? Also, how does one get the rubber seal off? I couldn't get that to budge a all. Any help would be appreciated. If I can't get it done on my own, I'll probably take it to the dealer and have them do it. I just don't want to dish out more cash when it's something I can do on my own. Thanks in advance.
I recently installed mine and had the same issue. I am not very mechanically inclined, but what I did was wiggle/rotate the old housing after releasing the 2 visible clips. It eventually worked it's way out. I did notice a very small "crack" in the sheet metal at about 7 o'clock on the cut out. Did not appear to be a big deal. New one popped right in. I love the new look!


