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The fuel door on a Ford Transit is prone to breaking, with many owners reporting that they have had to replace theirs. The hinge is a common point of failure, but the entire door can also break off. Ford dealers stock the replacement part, which costs around $100, but some owners have reported being quoted a few hundred dollars for the repair. There are also DIY fixes that can be done, such as using velcro or tie-wraps to secure the door.
| Characteristics | Values |
|---|---|
| Hinge repair | Align 3M DualLock pieces, then press the fuel door closed |
| Fuel door replacement part | Available at Ford dealers |
| Cost | Around $100-$200 |
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What You'll Learn
How to fix a broken fuel door hinge
If the hinge on your Ford Transit fuel door is broken, you may need to replace the entire door. Many Ford dealers stock the fuel door replacement part, so you can simply buy a new one and fit it yourself.
There are also some temporary fixes you can try. One suggestion is to use 3M DualLock to press the fuel door closed. This ensures that the DualLock is properly aligned. However, one user reported that adding a tie-wrap caused the fuel door to become slightly misaligned, resulting in the DualLock gripping even more tightly when the door is closed. Another suggestion is to use the new type of velcro with "L" shaped stems to fix the door.
If you want to attempt to repair the hinge, one user suggested that it might be possible to make a new one out of 3D-printed nylon or PVC.
There is also a video on YouTube by Med Tec67 which shows how to remove and replace the entire Transit Fuel door assembly/panel.
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How to remove the fuel door assembly
To remove the fuel door assembly on a Ford Transit, you will need to follow these steps:
- Locate the two pieces of 3M DualLock.
- Press the fuel door closed to ensure the DualLock is properly aligned.
- If the fuel door is slightly misaligned, add a tie-wrap solution. This will cause the DualLock to grip more tightly when the fuel door is closed.
- If the hinge is broken, you may need to replace the entire fuel door assembly.
- You can purchase a replacement fuel door from a Ford dealer or online.
- If you are installing an onboard airbag system, you may need to remove the fuel door assembly to access the manual fill Schrader valves behind the pop-off trim panel immediately below the fuel door.
It is important to note that the fuel doors on Ford Transits lock as the driver's door closes. Be careful not to catch your pants on the plastic hinge as you exit the vehicle, as this can cause the hinge to break.
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Where to buy a replacement fuel door
To replace a Ford Transit fuel door, you can either fix the hinge or replace the entire door.
You can buy a replacement fuel door for a Ford Transit from Amazon or from a Ford dealer. The part is stocked by many Ford dealers and can be purchased for around $100. Amazon offers free delivery on eligible purchases.
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How to align the fuel door
If the fuel door is misaligned, it may be necessary to replace the entire door. This can be done by purchasing a replacement part from a Ford dealer. However, if the door is only slightly misaligned, it may be possible to adjust it by locating the two pieces of 3M DualLock and pressing the fuel door closed. This will ensure that the DualLock is properly aligned.
If the fuel door hinge is broken, it may be possible to repair it without replacing the entire door. One possible solution is to use zip ties to secure the door in place. Another option is to use the new type of velcro with "L" shaped stems to fix the door.
If the fuel door is completely broken off, a fuel panel replacement may be necessary. This can be done by removing the entire Transit Fuel door assembly/panel and installing a new one. It may also be possible to install air bag Schrader valves in a hidden location behind the fuel door.
For slider door alignment, it is important to note the number of bolts used for the rear-middle adjustment. Ford uses three bolts, even though two could carry the load. This suggests that the outer two bolts can pivot on the middle bolt to accomplish some degree of door alignment. Additionally, when the door is open, there is only one attachment point at the back, in the middle. Applying moderate pressure to the bottom of the door when it is closed can help with alignment, but it will not stay in place when the pressure is relieved.
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How to fix a broken gas tank door
If your gas tank door is broken, you may need to replace the entire door or just the hinge. You can buy a replacement part from a Ford dealer. You can then follow a video tutorial to remove and replace the entire Transit Fuel door assembly/panel.
If you are repairing the hinge, you can use 3M DualLock to press the fuel door closed. This ensures that the DualLock is properly aligned. However, this may cause the fuel door to be slightly misaligned when closed, causing the DualLock to grip more tightly.
If you are repairing the door, one solution is to use the new type of velcro with "L"-shaped stems.
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Frequently asked questions
The cost of a replacement fuel door for a Ford Transit can vary. One user reported that they were quoted a few hundred dollars by Ford, while another user paid $119 for a replacement door. Another user paid $102 for the replacement part.
Yes, a lot of Ford dealers stock the fuel door replacement part.
Yes, there is a video on YouTube by Med Tec67 called "Ford Transit fuel door replacement" which has almost 10K views.
If your fuel door is misaligned, you can try to fix it by locating the two pieces of 3M DualLock and pressing the fuel door closed. This will ensure that the DualLock is properly aligned.
