Ford Explorer: Body Closures / Removal and Installation - Fuel Filler Door Assembly

Special Tool(s) / General Equipment

Removal

NOTE: Removal steps in this procedure may contain installation details.

NOTE: The fuel filler door assembly is damaged during the removal process and requires a new fuel filler door assembly installed.

1. Remove the fuel filler door.
   Refer to: Fuel Filler Door (501-03 Body Closures, Removal and Installation).
   

1. With the vehicle in NEUTRAL, position it on a hoist.
   Refer to: Jacking and Lifting - Overview (100-02 Jacking and Lifting, Description and Operation).
   

1. Remove the LHR wheel and tire. Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
   

1. • Remove the nuts.
     Torque: 22 lb.in (2.5 Nm)
   • Remove the screws.
     Torque: 13 lb.in (1.5 Nm)
   • Remove the bolt.
     Torque: 89 lb.in (10 Nm)
   • Remove the LHR wheel liner.
     

1. Loosen the clamp and disconnect the hose. Position the hose aside.
   Torque: 28 lb.in (3.2 Nm)

1. Remove the quick release couplings.
   Refer to: Quick Release Coupling (310-00A Fuel System - General Information - 2.3L EcoBoost (201kW/273PS), General Procedures).
   

1. NOTE: Use new bolts.

   • Remove and discard the bolts.
     Torque: 80 lb.in (9 Nm)
   • Position the fuel tank filler pipe and drain hose assembly aside.
     

1. Using a knife, slice the holes in the indicated areas.
   Use the General Equipment: Knife

1. Insert the screwdriver and release the clips while pulling the fuel filler door housing away from the vehicle.
   Use the General Equipment: Flat Headed Screw Driver

1. 
   
   • Pull the fuel filler door housing away from the vehicle to disconnect the electrical connector and drain hose.
     
   • Position the fuel filler neck as needed to remove the fuel filler door assembly.
     

Installation

1. To install, reverse the removal procedure.