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Need help with stuck fuel cap.

Old 03-03-2019, 06:48 AM
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Default Need help with stuck fuel cap.

I have a locking fuel cap which I never lock and it is stuck. In the locked position the cap just spins freely. Unlocked, something engages inside allowing you to unscrew it. Mine is stuck to the point that I have to turn it so hard that the internal mechanism just skips a tooth or whatever is in there. Has anyone experienced this? It appears to be made of plastic. Could I just try to break the cap out and replace it? Attached is a photo showing the cap.

Thanks.
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Old 03-03-2019, 07:08 AM
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Is there a access panel so you can get to the hose clamp and replace the cap and base for a normal one ?
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Old 03-03-2019, 07:38 AM
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Originally Posted by mitchell master View Post
Is there a access panel so you can get to the hose clamp and replace the cap and base for a normal one ?
Thanks for the reply. I can stand on my head and reach the clamps. I thought of doing just what you suggested. I was hoping to just dig the old cap out without screwing up the female threads and just replace the cap. Worst case I would have to replace the whole fill tube assembly.


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Old 03-03-2019, 07:46 AM
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Can you drill a 1/8” hole through both parts and pin it allowing the inside to spin?

Try not to get plastic shavings in the tank.
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Old 03-03-2019, 07:51 AM
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Originally Posted by Bryan A. View Post
Can you drill a 1/8” hole through both parts and pin it allowing the inside to spin?

Try not to get plastic shavings in the tank.
Thanks, that’s a good idea. I’ll try that before I go digging at it. Just not sure what the inside mechanism looks like.
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Old 03-03-2019, 08:05 AM
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Use a hand drill or pneumatic drill, not an electric one.
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Old 03-03-2019, 08:18 AM
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Originally Posted by Bryan A. View Post
Can you drill a 1/8” hole through both parts and pin it allowing the inside to spin?

Try not to get plastic shavings in the tank.
had to do this on a few locking gas caps on my jeep. Easy
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Old 03-03-2019, 08:31 AM
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Heat with a hair dryer? The plastic should get softer, maybe release.
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Old 03-03-2019, 10:39 AM
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Old 03-03-2019, 02:53 PM
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Originally Posted by tkane View Post
Heat with a hair dryer? The plastic should get softer, maybe release.
might be worth a try before I destroy it.

Thanks.
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Old 03-03-2019, 02:55 PM
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Originally Posted by Thalasso View Post
Thanks, I’ll give that a try if the hair dryer trick doesn’t work. Probably won’t be able to try before next weekend.

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Old 03-04-2019, 10:57 AM
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Hair dryer and fuel fumes - good combination. Why not use a torch , it will be quicker?
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Old 03-04-2019, 11:11 AM
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Originally Posted by satbeachbill View Post
Hair dryer and fuel fumes - good combination. Why not use a torch , it will be quicker?
That was my thought when I advised to not use an electric drill. But, let's just hold his beer and stand back.

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Old 03-04-2019, 11:34 AM
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Abrasive wheel on a Dremel tool should do the trick.
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Old 03-04-2019, 11:42 AM
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Don't use flames or Glowing red wires like inside a hair dryer. Plastics I'd use a hand operated drill instead of electric. Or at least go slow.

That video posted was The Chit.
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Old 03-04-2019, 01:04 PM
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Why not remove the screws holding it to the deck and see if you can pull it out far enough to get at the hose clamp, and just replace it? If there is not enough slack in the hose, you might be able to loosen the end of the hose at the tank just to get it to move enough. I would NOT use an electric drill or heat....
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Old 03-15-2019, 09:25 PM
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Here's an update. I did manage to get the cap off. As was suggested, after spraying a bit of penetrating oil around the cap, I heated it a bit with a hairdryer. Then with the help of a wrench, I was able to pop it loose. I will not be reusing that cap. I never locked the cap so I am going with a plain, non-locking cap. Thanks for all of the suggestions.
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