Fuel Filler Fix - solution found and engineered

[steved57]

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

Ok and Thanks - Look forward to seeing you and Roz

 

[mymach5]

I live in Melbourne Fl and have repaired my little flapper. If anybody wants to come by my house with their car to have me "help" them fix it I am happy to do so. It will cost you a bottle of Woodford.

 

[HighHP]

What problem did you encounter with the flapper? Did you fix it from top or did you pull the inner fender and remove the unit?

 

[roketman]

Very impressive! Thanks for sharing!

 

[Tommie]

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.

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

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

May I have the part# for the f150 part
Thanks

 

[GT@50]

I'm doing one now. The lock tab that holds the flap and hinge in place is weak and let it fall out. This is no big deal to resolve. Problem is that the O ring has a cut in it. Has anybody found a replacement O ring? It's not a typical ring. The ID is flat and thin to fit in a receiver groove in the flap leaving a typical O ring shape exposed to seal it.

 

[twobjshelbys]

I'm doing one now. The lock tab that holds the flap and hinge in place is weak and let it fall out. This is no big deal to resolve. Problem is that the O ring has a cut in it. Has anybody found a replacement O ring? It's not a typical ring. The ID is flat and thin to fit in a receiver groove in the flap leaving a typical O ring shape exposed to seal it.

Have you tried specialty o ring places like theoringstore.com, captainoring.com, and alloring.com. I needed some for my pool but can't remember the place right now but will check 8n the morning

 

[Shark01]

I bet Captain O ring is fun at parties…..

 

[twobjshelbys]

my last order was from oringsandmore.com

 

[GT@50]

Here's the o ring

 

[GT@50]

screws come down through slider assy into fill tubeflapper assy only goes into tube one wayI'll file a slight angle on tab and receiver hole to encourage engagement when pushed down while filling Flap tab can't be pushed out past o ring diameter so it doesn't hook very well. Good spot for some epoxy to keep flapper from falling out again.fender liner was not that bad. I did use a heat gun

 

[GT101]

Just a reminder that we have the flap and retaining bracket available in 3D printed aluminium on our store here:

Ford GT fuel filler neck repair kit

Replacement fuel filler flap and bracket. The OE parts inside the fuel filler neck are plastic and prone to failure. These parts are direct replacements 3D printed in aluminium. Please note that this is a fairly tricky repair procedure.The fuel filler neck assembly must be removed from the...

gt101.store

You will need to reuse the spring, pivot pin and O ring. If anyone comes up with a part number for the O ring do let us know.

 

[twobjshelbys]

That's not an o-ring in the traditional sense. More like a formed ring and washer. You could try sending a pic to oringsandmore (i say them because their site lists similar assemblies for other auto mfgrs but not ford) but I think you'll need to locate ford's original source. Good luck

 

[HighHP]

I am confused. I see two different rubber sealing rings. Did you find a suitable replacement or is that a second rubber ring?

 

[GT@50]

I am confused. I see two different rubber sealing rings. Did you find a suitable replacement or is that a second rubber ring?

Same ring, top and bottom pics of it.

 

[texas mongrel]

Given that Ford is the only one with this kind of "clever filler" I'm guessing that a trip to a friendly ford parts department with the old ring will yield a similar one from another model. The GT used all kinds of parts from F150s, Expeditions etc, so that gasket may have come from somewhere else....

 

[GT@50]

This is a 2010 F150. I don't want to make that work. I sent the tube to my dealer to show techs to see if any other car had a similar set up that might be had for less than $1800 and made to work. Where do we get a cork? Lol

 

[GT@50]

I can have the O rings reproduced for about $1700. Are they worth $170 each?

 

[HighHP]

Probably - when someone needs it. But until then? I guess your question is - will anyone pay $170 to have one on hand?

 

[2112]

I will pay that