• Welcome to the Contour Enthusiasts Group, the best resource for the Ford Contour and Mercury Mystique.

    You can register to join the community.

Billet Mustang Fuel Door w/o body damage

guzzi svt

New CEG'er
Joined
May 7, 2007
Messages
11
Location
Kansas City
Instructions for installing the Mustang aluminum fuel door without body damage and retaining fuel door assembly
1. Open the fuel door
2. Remove the gas cap
3. Remove 8mm gas cap tether screw
3. Rotate fuel door assembly CCW 30 degrees and remove disconnecting rubber hose
4. Remove the fuel door from the assembly
a. Split the small housing that has the rubber hose connection by prying the perimeter loose with pliers
b. Insert a screwdriver between the two pieces and pry then apart
c. Stick a screwdriver in to the door’s pivot point and spread the assembly so it releases the door
5. Glue the two pieces back together
6. Remove all of the mounting screws from the new fuel cover mounting ring
7. Using a grinder or file remove the two raised areas on the back of the new mounting ring where the long screws were. The back of the new mounting ring should be smooth.
8. On the face of the existing fuel door assembly, right where the rubber gasket ends there is a small raised lip. This must be trimmed away to allow the new mounting ring to set flush on the rubber gasket.
9. Align the new fuel door on the old fuel door assembly so that the hinge is on the right side, same as the old one. Temporarily reinstall the fuel assembly maybe a good idea at this time to be sure you get the new door on straight.
10. Drill small pilot holes thought the old assembly using the new fuel door ring as a template. Remove the assemble from the car.
11. Drill the top and bottom mounting holes with a bit large enough to allow the long screws to go all the way through.
12. Insert long screws into these holes and add two washer spacers to each with a nut. The washers will need to be trimmed on both sides to allow them to fit down close to the hole in the assembly.
13. Drill the remaining hole just large enough to screw the remaining short screws in the plastic assembly.
Some glue should be added to these to hold them in. Two of the holes will line-up with the mounting tabs of the assembly, do not be drilled through the tabs.
14. Reattach rubber hose and reinstall fuel door assembly clock wise with new the aluminum door attached.
15. Reinstall the fuel cap tether screw and your done.
 
Back
Top