Fuel Filler Fix - solution found and engineered


BlackICE

GT Owner
Nov 2, 2005
1,415
SF Bay Area in California
IMHO, replace the OEM with OEM and be careful when filling up. Much, much larger percentage of cars having no problems at all as opposed to those who have experienced a problem. The odds are in your favor.
I :agree: with a large emphasis on being "careful when filling up".
 

spddmnjay

GT Owner
Mark II Lifetime
Feb 14, 2008
422
Alberta, Canada
Yes, it was a fuel sensor safe RTV silicone that I used.

Thanks for your comments Bill. :thumbsup
 

MNJason

GT Owner
May 14, 2010
2,036
Twin Cities
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!
 

Bill Briley

GT Owner
Aug 9, 2005
212
Valley Forge PA.
Spend the whole afternoon today on my filler neck.
I believed that may be there was no damage to the flapper mecanism.
I managed to get the inserted piece out without breaking it. And I was right! Nothing broken. Assembling the loose flapper pieces took me 2 minutes:banana:banana:banana. I guess that in most of the cases, nothing is broken. :cheers:cheers
I will publish some pictures later on.

Sure would like to see thoes pictures.
 

viva gt

GT Owner
Sep 15, 2010
408
toronto canada
found same issue as others. flapper back in place and secured. now the fun part of putting the inner fender back into place.
should be driving tomorrow.
FYI..the filler neck assembly is not in stock at ford or its distribution. being told 8 - 12 weeks. i placed an order anyways just so i will have one for the future,, just in case.
thanks go out to "Pro_GT driver" for guidance on this repair.
 
Last edited:

Bill Briley

GT Owner
Aug 9, 2005
212
Valley Forge PA.
 

spddmnjay

GT Owner
Mark II Lifetime
Feb 14, 2008
422
Alberta, Canada
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.
 

Beach-GT

GT Owner
Mark II Lifetime
May 8, 2006
883
Seminole Florida
How about a cork?
 
Aug 25, 2006
4,436
Yes, it was a fuel sensor safe RTV silicone that I used.

Thanks for your comments Bill. :thumbsup
You are welcome

I have always liked the fact that you are willing and do operate "outside of the proverbial box"; and you share that which you do.

Takes care

Shadowman
 

ItsDocJim

Active member
Aug 12, 2017
37
So I have the same issue. I told the dealership the problem was the flapper and pin but they wouldn't listen. I brought in the pages from the forum and told them I talked to some of the engineers but they didn't care, told me I was wrong and replaced a fuel canister or something for well over $700. Half a tank of gas later, light is back on and same error code. They say the filler neck assembly is back ordered and the repair will be about $2800... ouch.

I do not know if I trust them to be able to mod a F150 part, but not sure what other options are out there.
 

ItsDocJim

Active member
Aug 12, 2017
37
So I have the same issue. I told the dealership the problem was the flapper and pin but they wouldn't listen. I brought in the pages from the forum and told them I talked to some of the engineers but they didn't care, told me I was wrong and replaced a fuel canister or something for well over $700. Half a tank of gas later, light is back on and same error code. They say the filler neck assembly is back ordered and the repair will be about $2800... ouch.

I do not know if I trust them to be able to mod a F150 part, but not sure what other options are out there.

Edit... I did notice that in the original post with the pics for the mod, it stated that "if this happens, then it wont start" however, I have not had a problem starting it. It just takes 20 minutes to fill with gas. Same problem/solution???
 

Shark01

GT Owner
Jul 22, 2012
263
Houston Texas
Edit... I did notice that in the original post with the pics for the mod, it stated that "if this happens, then it wont start" however, I have not had a problem starting it. It just takes 20 minutes to fill with gas. Same problem/solution???
This is my issue also, always starts, always takes forever to put gas in.
 

gtjoey

Keep Smiling - GT Owner
Mark IV Lifetime
Oct 14, 2005
3,429
Well GTJOEY was the first that the filler flap broke.......300 miles on the car and the car stalled at a 4 way crossing......
My great friend, Fred Goodnow, had a NEW PIPE shipped out before the very first rally and a YOUNG MAN named DENIS Breitenbach walked the local dealer through the process.
If you jammed the nozzle to deep into the opening you can SNAP the springs which happened in my case. leaving the lower flaps down , sucking in air. Both Rich and Denis had made tools to replace the pipe WITHOUT removing the fender. The third bolt was behind the pipe.
Passenger wheel removed, inner liner removed, watching not to bend the lip, a couple of brackets removed and that was it.
YOU NEED THE NEW PIPE! It will stall and send a check engine code at the wrong time. unless your tank is FULL you will get a light and stall.
The evap loop starts after 3/4 and below.
My gift for not getting seriuosly hurt was a wonderful FORD GT filler cap prototype!
Which has been on my car ever since.
gtjoey1314
 

Shark01

GT Owner
Jul 22, 2012
263
Houston Texas
Just to further explain what my car exhibits, in addition to the slow fill ups, my idle is very erratic when coming to a stop, sometimes taking the RPMs down to nearly 0, stalls occasionally but always re-starts. I thought that was another problem but have seen one or two people on the thread mention it.

There are a few methods described here for a fix (F150 filler, some pipe (I don’t understand this one), even cork?) is there a consensus for the best way to fix it? Thanks
 
  • Like
Reactions: viva gt

viva gt

GT Owner
Sep 15, 2010
408
toronto canada
Just to further explain what my car exhibits, in addition to the slow fill ups, my idle is very erratic when coming to a stop, sometimes taking the RPMs down to nearly 0, stalls occasionally but always re-starts. I thought that was another problem but have seen one or two people on the thread mention it.

There are a few methods described here for a fix (F150 filler, some pipe (I don’t understand this one), even cork?) is there a consensus for the best way to fix it? Thanks
Easiest way (short of buying a new one,,,if available) is to take it out then take it apart and put the flapper back together. Rough sand or scratch with a knife, the tongue part and its receiving part then apply a gas resistant sealant and reassemble.
I did mine a 3 years ago and it is still together.
The hardest part for me ( besides taking out the freaking inner fender) was locating a 5.5 mm combo wrench to take the screws out of the fill cap/ flap housing.
I might have an instruction email from an overseas member (Pro_GT) that I can share.
pm me your email and I will check to see if I can locate it.
 

texas mongrel

GT Owner
Mark II Lifetime
May 3, 2009
1,498
Houston Texas
My fix was to pull the filler pipe, as described many times in this forum, then re-assemble the flapper and run a #8 screw through the plastic hinge and into the pipe. This prevents the flapper assembly from dismantling itself again when a gas hose nozzle bumps into it. I did this fix about five years ago and have had no problems since. Pulling the fender liner is no big deal, just fiddly and requiring commitment to turn it into a pretzel as you pull it out.
 
  • Like
Reactions: steved57

extrap

GT Owner
Mark II Lifetime
Jul 16, 2020
339
N Cent FL
Can somebody give me guidance on how exactly to be careful when filling up? ie barely stick the nozzle in? Favor more to one side or the other? Insert it very slowly / gently? Pray to the Gods? Eye of newt? Got my '05 late August and haven't had to fill up yet, and this thread has me a little nervous! o_O :)
 

twobjshelbys

GT Owner
Jul 26, 2010
5,360
Las Vegas, NV
I had one of these types on another vehicle too. I always just put the nozzle in straight and didn't let the hose put too much pressure/tension on the handle so it doesn't try to move the nozzle inside the tube.
 

steved57

GT Owner
Mark IV Lifetime
Le Mans 2010 Supporter
Mar 29, 2008
1,816
kilgore tx
My fix was to pull the filler pipe, as described many times in this forum, then re-assemble the flapper and run a #8 screw through the plastic hinge and into the pipe. This prevents the flapper assembly from dismantling itself again when a gas hose nozzle bumps into it. I did this fix about five years ago and have had no problems since. Pulling the fender liner is no big deal, just fiddly and requiring commitment to turn it into a pretzel as you pull it out.
I still need you to help me fix mine :)
 

texas mongrel

GT Owner
Mark II Lifetime
May 3, 2009
1,498
Houston Texas
I still need you to help me fix mine :)
Ha! Steve, once my workshop is clean of the Rolls project, come on down. I’m hoping my shop will be freed-up before year-end