Rajan Wilcox
Replacing the fuel door cover on a Ford F150 is a relatively simple task. The first step is to open the fuel door and remove the fuel filler door by prying lightly on the tab inside the door and sliding the door out towards you. You can then drill the holes and drill a slot shape where the indentions were to break the tabs holding the fuel door. After that, you can slide the new fuel door assembly in and slide the rubber part over your fuel neck. Finally, you can reinstall your fuel door cover and fuel door pin, shut the door, and you're done!
| Characteristics | Values |
|---|---|
| First step | Open the fuel door and remove the fuel filler door by prying lightly on the tab inside the door and sliding the door out towards you |
| Second step | Drill the holes and then drill a slot shape where the indentions were to break the tabs holding the fuel door |
| Third step | Take the fuel door assembly out by pulling it to the right side and sliding/pulling it out |
| Fourth step | Take your new fuel door assembly and slide it in like it came out, and slide the rubber part over your fuel neck and simply push it on in |
| Fifth step | Reinstall your fuel door cover and fuel door pin that came with the new assembly or preferably the mega ohm replacement |
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What You'll Learn
Removing the old fuel door cover
To remove the old fuel door cover, first open the fuel door. Then, press the tab with a screwdriver and slide the old door away from the hinge. Drill the holes and then drill a slot shape where the indentions were to break the tabs holding the fuel door. Drill slots in all five holes, then stick a slotted screwdriver into the holes and break the tabs. Be careful not to bend the sheet metal in the area. You should then be able to take the fuel door assembly out by pulling it to the right side and sliding/pulling it out. The assembly is partially rubber where the fuel neck sticks out, so you should be able to just pull it over your fuel neck and off.
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Drilling the holes
Before you begin drilling, it's important to mark the locations of the holes accurately. If you can't see the indentations clearly, use visible paint to mark the spots where you need to drill. This ensures that you don't drill in the wrong places and damage your vehicle.
Once you have your markings in place, it's time to get your drill ready. The user who shared their experience in the forum post used a 3/16 drill bit with a Dewalt drill to get the job done. Choose a drill bit size that matches the screws or fasteners you'll be using for the new fuel door cover.
Now, carefully drill the holes at the marked locations. Take your time and apply gentle pressure to ensure you don't damage the surrounding sheet metal. After drilling each hole, clear away any metal shavings or debris to keep the work area clean and prevent any issues during reassembly.
After drilling the holes, you'll need to drill a slot shape where the indentations were. This step is crucial for breaking the tabs that hold the fuel door in place. Drill slots in all the holes, and then use a slotted screwdriver to carefully break the tabs. Be extremely cautious during this step, as applying too much force can bend the sheet metal in the area.
By following these steps, you'll be able to successfully drill the holes needed to replace the fuel door cover on your Ford F150. Remember to work slowly and carefully to avoid any damage to your vehicle. Always wear appropriate safety gear, including eye protection, when working with power tools.
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Breaking the tabs
To break the tabs holding the fuel door, you will need to drill the holes and then drill a slot shape where the indentions were. You can then stick a slotted screwdriver into the holes and break the tabs. Be careful not to bend the sheet metal in the area by prying too hard.
To remove the fuel filler door, you can open the fuel door and then pry lightly on the tab inside the door. Slide the door out towards you. You can then press the tab with a screwdriver and slide the old door away from the hinge.
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Sliding the new door into place
To slide the new door into place, you will need to open the fuel door and press the tab with a screwdriver. Then, slide the new door into place. The assembly is partially rubber where the fuel neck sticks out, so you should be able to pull it over your fuel neck and push it on.
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Reinstalling the fuel door cover
To reinstall the fuel door cover, you will need to slide the new fuel door assembly into place. Make sure it is seated correctly with a tug and a pull, and then reinstall the fuel door cover and fuel door pin that came with the new assembly. Shut the door and you're done.
If you are not able to see the indentions, you can mark out your holes with visible paint. Get your drill or dremel ready and drill the holes. Drill a slot shape where the indentions were to break the tabs holding the fuel door. Drill slots in all five holes and then stick a slotted screwdriver into the holes to break the tabs. Be careful not to bend the sheet metal in the area.
The assembly is partially rubber where the fuel neck sticks out, so you should be able to just pull it over your fuel neck and off. Take your new fuel door assembly and slide it in like it came out, and slide the rubber part over your fuel neck and push it on.
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Frequently asked questions
Open the fuel door and remove the fuel filler door by prying lightly on the tab inside the door and sliding the door out towards you.
Slide the new door into place and push it on.
You will need a drill or dremel, a screwdriver, and a slotted screwdriver.
