Help with Stuck Fuel Door

My Gen 1 fuel door used to stick. I tried a lot of things including replacing the spring. What finally did it was just getting a good, light lube really into the hinges. The hinges aren't really built to be easily lubed, the gaps are too small for anything but a very light oil to get in. I happened to have a decades-old can of something called Tef-Lube I think I once bought at a bike shop.

I'd have expected your WD-40 to help, too. Maybe try it again, using the little straw and shooting right for the gaps in the hinges, and working them back and forth many times?

Up until I tried the Tef-Lube, my best trick was to get out of the car, bend my REI card and stick it in the gap around the corner of the filler door, then walk back up front and pull the release. After hearing the sproing and the card hitting the ground, I'd go back, pocket the card, and fill the tank.

After the Tef-Lube, never any more problems; the release would pop it open by inches every time.

-Chap

 

WD40 is more of a solvent than a lubricant. Try some white lithium grease. Clearance on the back side of the door is too tight. Either the door isn't flush with the rest of the car or it doesn't open fully and scratches the back side. I have to lube and bend the support bar every other year or so. Very annoying, but fixable.

 

I'm having the same trouble with the gas tank door not opening when pulling the lever.
Called my mechanics and its $252 min for them to look at and fix! So very grateful to find this chat!

Question - how does one put the Tef Lube or lithium grease on the hinges? There is nothing visible from outside the gas fill door - can it be lubed only after you got it open with the spray? Nance

 

Yes you will have to push it open.