Question about 2003 Volvo S60

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Fuel tank door hinge

How do I remove the broken fuel tank door hinge? Does it pry out? Is there access through the right rear wheel wheel? There does not appear to be access from inside the trunk. Thanks

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  • 2 more comments 
  • vincent v Jul 22, 2008

    I was getting gas and the attendant pushed my fuel door off its hinges.

    I have not been able to re connect it.

    Any hints?

  • Anonymous Apr 29, 2009

    where can I buy a replacement of the fuel tank door for my town&country 1996/or get new hinges

  • Anonymous Mar 31, 2014

    how do you replace the fuel door on 2005 chevy malibu

  • Anonymous Mar 31, 2014

    how do you replace fuel door hinge on 2005 malibu

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[Removing/Repairing Gas Filler Door Hinge: Tip from Bill Peyton]   The gas door hinge will break if pushed forward.  This is usually done by moving around the car with the door open, or by curious children.  The repair job can be done completely from the exterior. 
 
The black plastic hinge is held in place by four plastic rods.  When pushed through the body of the car, they expand four rubber sleeves located on the interior, thereby holding the whole thing in place. 
Remove as follows: 
Open the door, and using a small punch, push the four plastic rods through to the interior of the car.  The door will now come out.  Note the position of the spring and the hinge.  Remove the spring from the old hinge, and either cut or pry our the old hinge.  This is a black plastic piece. 
The ends of the new hinge are tapered to make it easier to insert into the gas door.  Clip the spring back into place. 
Now for the hard part.  You will see on the new hinge four plastic rods.  These are held onto the hinge by four small connections, all molded into a single piece.  On the other side of the hinge are four plastic “flowers” split into four pieces.  You will need to push the plastic rods through the “flowers”, once the “flowers” are pushed through to the interior of the car.   Since the rods are not free floating, they tend to break off and fly away unless you hit them squarely.  If this happens, put a little taper in the ends, place them back in the hold, and push them through.  A punch and a hammer will be essential.  Alternatively, you can break the rods off while the piece is off the car, insert them manually, and drive them in again with the punch.
 

Posted on Jul 07, 2008

  • gregorh Mar 13, 2011

    The black plastic hinge is about $10. The plastic rods are really tiny -- about 1/16 inch diameter and 3/8 inch long. My gas door just fell off. You can use a small nail to punch out the old rods. Then snap the new door hinge onto the door making sure the spring is on the correct side. Bend the spring down to snap it into place on the two projecting hooks. Then you can place it on the car, with the expansion "flowers" fitting into the old holes on the car body. Push in the top and bottom rods first because they are most accessible. You dont need a hammer. Just push them in holding them with a needle nose pliers. A hammer is over-kill for these small plastic bits until they are already almost completely inserted flush. As noted above, for the other two, it helps to file down the edges so that they start more easily. You can push them in with the pliers. To make them flush you can tap them with a nail (as punch) and hammer.

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