A Simple Guide To Replacing Your Ford Transit Fuel Door

The fuel door on a Ford Transit is prone to breaking, with many owners reporting issues with the hinge design. The door can be replaced with a new one, but this may cost a few hundred dollars. There are also temporary fixes that owners can perform themselves, such as using zip ties or wire to repair the hinge.

Repairing a broken hinge with a zip tie

If you're looking to replace a broken fuel door on your Ford Transit, you might be facing a few hundred dollars in repair costs. However, some people on the Ford Transit USA Forum have shared a more affordable solution: repairing a broken hinge with a zip tie. Here's a detailed, step-by-step guide on how to tackle this repair yourself:

Step 1: Assess the Damage

Before starting the repair, it's important to identify which hinge or hinges are broken. In some cases, only the top hinge may be broken, while in others, both the top and lower hinges may require attention.

Step 2: Gather Your Materials and Tools

For this repair, you'll need a few supplies:

• Zip ties (also known as cable ties)
• A drill
• A Dremel tool (optional)

Step 3: Prepare the Zip Ties

Take one zip tie and drill a hole at one end. This hole will act as a means of securing the zip tie to the hinge. Ensure the hole is large enough to accommodate the zip tie's width.

Step 4: Attach the Zip Tie to the Hinge

Feed the zip tie through the existing screw hole in the hinge. Pass it from the inside of the fuel door to the outside, ensuring the zip tie's head is accessible for tightening.

Step 5: Secure the Zip Tie

Tighten the zip tie securely, ensuring it is snug and holds the hinge in place. You may need to cut off any excess length, leaving just enough to ensure a firm hold. If the big end of the zip tie interferes with the fuel door's closure, use a Dremel tool to carefully remove any interfering material.

Step 6: Test and Adjust

Once the zip tie is in place, test the fuel door's operation. Ensure it opens and closes smoothly and that the zip tie doesn't obstruct the door's movement. If needed, adjust the zip tie's position or trim any interfering material with the Dremel tool.

By following these steps, you can repair a broken fuel door hinge on your Ford Transit using zip ties. This method has proven effective for several Ford Transit owners, offering a more robust connection than the original Ford design. Remember to work carefully and safely when performing any DIY repairs, and always ensure your vehicle is parked and turned off before beginning any work.

Replacing the entire fuel door

If your Ford Transit fuel door is beyond repair, you may need to replace the entire unit. This can be done by following these steps:

Step 1: Purchase a Replacement Fuel Door

First, you will need to source a replacement fuel door. These can be purchased from Ford dealerships, as well as some auto parts stores and online retailers. Make sure to get the correct part for your specific Ford Transit model and year.

Step 2: Remove the Old Fuel Door

The next step is to remove the old, broken fuel door. This process will vary depending on your vehicle, but it typically involves unscrewing or unbolting the old door from the vehicle's body. You may need to remove any remaining pieces of the broken door before attaching the new one.

Step 3: Prepare the New Fuel Door

Before installing the new fuel door, you may need to paint it to match the colour of your vehicle. This can be done with automotive paint, following the manufacturer's instructions.

Step 4: Install the New Fuel Door

Now, you can install the new fuel door. This process will be the reverse of the removal process, and typically involves screwing or bolting the new door into place. Ensure that the door is securely attached before closing it.

Step 5: Test the New Fuel Door

Once the new fuel door is installed, you should test it to ensure it is functioning correctly. Open and close the door several times to ensure it is secure and operating smoothly.

By following these steps, you can replace the entire fuel door on your Ford Transit. This process may vary slightly depending on your specific vehicle and the replacement part you have purchased, so always refer to the manufacturer's instructions and seek professional advice if needed.

Drilling a small hole and using wire to fix a hinge

Step 1: Assess the Damage

Before beginning the repair, it is important to assess the damage to the fuel door and identify which parts need to be repaired or replaced. In this case, the hinge is broken, so the focus will be on fixing or replacing it.

Step 2: Gather Tools and Materials

You will need a few tools and materials to complete this repair:

• Drill
• Small drill bit (appropriate for the size of wire/screw you will use)
• Wire (strong enough to support the fuel door)
• Screwdriver
• Screws (optional)
• Pliers or wire cutters
• Safety goggles and gloves

Step 3: Drill a Small Hole

Put on your safety goggles and gloves to protect yourself from any debris. Using the drill and small drill bit, carefully drill a hole in the fuel door and/or the vehicle body where the hinge will be attached. The location of the hole will depend on the specific configuration of your fuel door and vehicle. Make sure the hole is drilled in a place that will provide a secure attachment point for the wire.

Step 4: Feed the Wire Through the Hole

Cut a length of wire that is long enough to feed through the hole and provide enough length to attach the fuel door securely. Use pliers or wire cutters to help feed the wire through the hole and position it as needed.

Step 5: Secure the Wire

Once the wire is in place, you can secure it by twisting the ends together or by using screws. If using screws, drill pilot holes and then screw through the wire to secure it to the fuel door and/or vehicle body. Make sure the wire is tight and securely attached before moving on.

Step 6: Test the Fuel Door

After the wire is secured, test the fuel door to ensure it opens and closes smoothly and is securely attached. Adjust the wire as needed to achieve the correct positioning and tension.

This repair method is a creative and cost-effective solution to a broken fuel door hinge. By drilling a small hole and using wire to create a new attachment point, you can fix the hinge and restore the functionality of the fuel door.

Using glue to fix a cover that doesn't fit well

I found a forum post from a user who had a similar issue with their Ford Transit fuel door. They said:

> "There is a Dorman replacement. Only issue I had was that my cover did not seem to fit well with it. Used a little glue and no issues."

If you're thinking of using glue to fix a cover that doesn't fit well, there are a few things to keep in mind. Firstly, it's important to select the right type of glue for the materials you're working with. For example, standard super glues are not always recommended for repairing glass as they can come apart with cleaning or general use. Instead, a specialised glass glue should be used for glass repairs.

Before gluing, it's crucial to ensure that the surfaces to be bonded are clean, dry, and free of any oil, wax, paint, or residue. Even fingerprints might prevent a strong bond from forming. It's also a good idea to test the fit of the surfaces and clear away any fragments or particles that could obstruct a perfect seal.

When you're ready to glue, apply a thin but consistent layer of glue to one of the surfaces. Press the surfaces together firmly and hold them in place for the recommended amount of time, which can vary depending on the type of glue you're using. Once the bond is set, leave the glued pieces undisturbed for at least 10 minutes to ensure a strong hold.

Finally, clean up any excess glue with a damp tissue or razor blade, being careful not to scratch the surfaces.

Buying a new fuel door from a junkyard

If you're looking to replace your Ford Transit fuel door, one option is to buy a new one from a junkyard. Junkyards are great places to find used car parts at a fraction of the cost of new ones. Here are some tips to help you buy a fuel door from a junkyard:

• Find a Junkyard Near You: Start by searching for junkyards in your area that specialize in used car parts. You can use online resources or simply Google "junkyards near me" to find options in your vicinity.
• Call Ahead: Once you've identified a few potential junkyards, give them a call to inquire about their inventory. Ask if they have fuel doors for your specific Ford Transit model and whether they are in good condition.
• Compare Prices: Don't settle for the first junkyard you find. Compare prices and the condition of the fuel doors at multiple locations to get the best deal.
• Inspect the Fuel Door: When you visit the junkyard, carefully inspect the fuel door before purchasing it. Ensure that it is in good condition, free from any major dents, rust, or other damage.
• Match the Color: If you want the fuel door to match the color of your Ford Transit, bring a sample of your car's paint with you to the junkyard. Compare the color of the fuel door to your car's paint to get as close a match as possible.
• Negotiate the Price: Junkyards are often open to negotiation, so don't be afraid to haggle a bit to get a better price. You may also be able to get a discount if you purchase multiple parts or if you're a returning customer.
• Return Policy: Before making the purchase, inquire about the junkyard's return policy. It's always good to have the option to return the part if it doesn't fit or function properly.
• Installation: Keep in mind that you may need to install the fuel door yourself or seek the help of a mechanic. Factor in the cost of installation when deciding on your budget.

By following these tips, you can find a great deal on a fuel door for your Ford Transit at a junkyard, saving you money while still getting a quality replacement part.

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