Fuel Filler Fix - solution found and engineered


spddmnjay

spddmnjay

GT Owner
Mark II Lifetime
Feb 14, 2008
422
Alberta, Canada
As most of us are aware, a common problem is the fuel filler door (round flapper door that opens) will break. When this happens the filler door breaks in the open position. Then the car will not start. Only solution is to purchase another complete fuel filler assembly from Ford.

So I took the opportunity to come up with a solution while my car is completely apart. I purchased a 2009 Ford F-150 fuel filler assembly to see if it would work. And it did! It worked perfectly!!

Please note that this is not a quick fix. I would like to share all that I have learnt in the process.

Original Ford GT fuel filler before modification.

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Ford GT fuel filler assembly and 2009 Ford F-150 fuel filler assembly before work began.

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Ford GT fuel filler door removal. Assembly was glued in and therfore needed to come out in pieces.

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F-150 fuel filler door removal from filler tube assembly. I should note that I had no idea how to take the assembly apart. I made sure to measure and carefully examine how the piece was assembled before making any cuts. Dremmel worked perfect!

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Ford F-150 piece installed into Ford GT fuel filler tube assembly. I sealed the piece with fuel sensor safe silicone.

I was absolutely amazed that the Ford F-150 dimensions were identical to the Ford GT. The F-150 door location was exactly in the same position as the Ford GT's. Plus the installed insertion is exactly the same as the GT's. Everything lined up perfect!

I did not remove the two posts on top of the assembly because they were part of the hinge design. These posts did not change the install height of the assembly and it fit flush up against the flange under the fender.

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Fuel filler installed into the Ford GT.

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Great job.

Now can you turn your attention to replacement tachs and headlights? :biggrin

.
 
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Reactions: Natee
very well done, great info. thanks for sharing.
 
How about a cork?
 
Excellent to know this, thanks!
 
Thanks for the comments guys. :thumbsup
 
How about a Cork????
This may be the quickest "fix" !!!

Would it work?
 
I'm sorry, is the GT part no longer available? Not sure I understand the need to mod the F150 part. Is the GT part too expensive or is the F150 part more robust? Thanks for taking the time to post details as I'm probably out of warranty.
 
DanQ said:
I'm sorry, is the GT part no longer available? Not sure I understand the need to mod the F150 part. Is the GT part too expensive or is the F150 part more robust? Thanks for taking the time to post details as I'm probably out of warranty.
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The idea is that the GT part is a potentially/probable/likely reoccurring pblm. The F150 part isn't. :wink
 
Empty Pockets said:
The idea is that the GT part is a potentially/probable/likely reoccurring pblm. The F150 part isn't. :wink
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100% Correct :thumbsup
 
How common is this problem?

I have a 2010 Ford as well and the "capless" filler is wonderful. MUCH better design, IMO, than the GT.

Of course they had 5 years to improve it!
 
Shadowman would probably know if this is a "common" problem. I also understand that Shadowman has designed a solution for this problem that incorporates a fuel cap.
 
I'm still going to try the cork if it happens to me.
 
Just for interest sake does anyone know the prices for the 2 units?
 
Legs, do you want it in Canadian or American $?
 
spddmnjay:

What type sealer did you use and how well has it held up thus far?
 
ViperJoe said:
spddmnjay:

What type sealer did you use and how well has it held up thus far?
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I would speculate that it was typical RTV and service life should be long; vapors within would be my only minor concern; meaning the vapors within eating at the RTV. If this approach is to be used there are many alternate bonding agents that would eliminate this concern.

spddmujay did a great job of this finding and adapting this solution and in saying this I can share first hand he likes to tinker with his gals as such for some, maybe many this will be the direction to take however IMO the best solution is a tradition fuel cap located under the OEM flap; this would allow for the ease of filling, the use of alternate fuels typically filled by jug, and it would never fail.

So will your fuel filler neck fail; IMO yes if you drive your gal. It is not a matter of if but rather when.

Takes care

Shadowman
 
Shadowman said:
I would speculate that it was typical RTV and service life should be long; vapors within would be my only minor concern; meaning the vapors within eating at the RTV. If this approach is to be used there are many alternate bonding agents that would eliminate this concern.

spddmujay did a great job of this finding and adapting this solution and in saying this I can share first hand he likes to tinker with his gals as such for some, maybe many this will be the direction to take however IMO the best solution is a tradition fuel cap located under the OEM flap; this would allow for the ease of filling, the use of alternate fuels typically filled by jug, and it would never fail.

So will your fuel filler neck fail; IMO yes if you drive your gal. It is not a matter of if but rather when.

Takes care

Shadowman
Click to expand...

Bill - I like the traditional cap solution. Is this something you have engineered and will be making available for sale?
 
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