Fuel Filler Fix - solution found and engineered


mymach5

GT Owner
Nov 18, 2007
36
Melbourne, Florida
I live in Melbourne Fl and have repaired my little flapper. If anybody wants to come by my house with their car to have me "help" them fix it I am happy to do so. It will cost you a bottle of Woodford.
 

HighHP

GT Owner
Jun 3, 2019
466
Spokane, WA
What problem did you encounter with the flapper? Did you fix it from top or did you pull the inner fender and remove the unit?
 

roketman

GT Owner
Mark IV Lifetime
Oct 24, 2005
8,079
ma.
Very impressive! Thanks for sharing!
 

Tommie

Member
Mar 7, 2020
5
As most of us are aware, a common problem is the fuel filler door (round flapper door that opens) will break. When this happens the filler door breaks in the open position. Then the car will not start. Only solution is to purchase another complete fuel filler assembly from Ford.

So I took the opportunity to come up with a solution while my car is completely apart. I purchased a 2009 Ford F-150 fuel filler assembly to see if it would work. And it did! It worked perfectly!!

Please note that this is not a quick fix. I would like to share all that I have learnt in the process.

Original Ford GT fuel filler before modification.

32748250177_large.jpg


32748250178_large.jpg


Ford GT fuel filler assembly and 2009 Ford F-150 fuel filler assembly before work began.

32748250173_large.jpg


Ford GT fuel filler door removal. Assembly was glued in and therfore needed to come out in pieces.

32748250179_large.jpg
May I have the part# for the f150 part
Thanks
 

GT@50

GT Owner
Mark II Lifetime
Dec 14, 2019
937
Issaquah
I'm doing one now. The lock tab that holds the flap and hinge in place is weak and let it fall out. This is no big deal to resolve. Problem is that the O ring has a cut in it. Has anybody found a replacement O ring? It's not a typical ring. The ID is flat and thin to fit in a receiver groove in the flap leaving a typical O ring shape exposed to seal it.
 

twobjshelbys

GT Owner
Jul 26, 2010
6,182
Las Vegas, NV
I'm doing one now. The lock tab that holds the flap and hinge in place is weak and let it fall out. This is no big deal to resolve. Problem is that the O ring has a cut in it. Has anybody found a replacement O ring? It's not a typical ring. The ID is flat and thin to fit in a receiver groove in the flap leaving a typical O ring shape exposed to seal it.
Have you tried specialty o ring places like theoringstore.com, captainoring.com, and alloring.com. I needed some for my pool but can't remember the place right now but will check 8n the morning
 
Last edited:

Shark01

GT Owner
Jul 22, 2012
599
Houston Texas
I bet Captain O ring is fun at parties…..
 

twobjshelbys

GT Owner
Jul 26, 2010
6,182
Las Vegas, NV
my last order was from oringsandmore.com
 

GT@50

GT Owner
Mark II Lifetime
Dec 14, 2019
937
Issaquah
Here's the o ringIMG_20230926_192802522.jpgIMG_20230926_192809585.jpgIMG_20230926_192834309.jpg
 

GT@50

GT Owner
Mark II Lifetime
Dec 14, 2019
937
Issaquah
IMG_20230926_192756862~2.jpgIMG_20230926_193309238~2.jpgscrews come down through slider assy into fill tubeIMG_20230926_193132517_HDR~3.jpgflapper assy only goes into tube one wayIMG_20230926_193139345~2.jpgIMG_20230926_192931559~2.jpgIMG_20230926_192956729_HDR~2.jpgI'll file a slight angle on tab and receiver hole to encourage engagement when pushed down while filling IMG_20230926_193011023~2.jpgFlap tab can't be pushed out past o ring diameter so it doesn't hook very well. Good spot for some epoxy to keep flapper from falling out again.IMG_20230926_193552463~2.jpgfender liner was not that bad. I did use a heat gun
 

GT101

*UK Support*
Supporting Vendor
Jan 20, 2010
393
Colchester, Essex, UK
Just a reminder that we have the flap and retaining bracket available in 3D printed aluminium on our store here:

You will need to reuse the spring, pivot pin and O ring. If anyone comes up with a part number for the O ring do let us know.
 
  • Like
Reactions: GT@50

twobjshelbys

GT Owner
Jul 26, 2010
6,182
Las Vegas, NV
That's not an o-ring in the traditional sense. More like a formed ring and washer. You could try sending a pic to oringsandmore (i say them because their site lists similar assemblies for other auto mfgrs but not ford) but I think you'll need to locate ford's original source. Good luck
 

HighHP

GT Owner
Jun 3, 2019
466
Spokane, WA
I am confused. I see two different rubber sealing rings. Did you find a suitable replacement or is that a second rubber ring?
 

GT@50

GT Owner
Mark II Lifetime
Dec 14, 2019
937
Issaquah
I am confused. I see two different rubber sealing rings. Did you find a suitable replacement or is that a second rubber ring?
Same ring, top and bottom pics of it.
 

texas mongrel

GT Owner
Mark II Lifetime
May 3, 2009
1,672
Houston Texas
Given that Ford is the only one with this kind of "clever filler" I'm guessing that a trip to a friendly ford parts department with the old ring will yield a similar one from another model. The GT used all kinds of parts from F150s, Expeditions etc, so that gasket may have come from somewhere else....
 

GT@50

GT Owner
Mark II Lifetime
Dec 14, 2019
937
Issaquah
This is a 2010 F150. I don't want to make that work. I sent the tube to my dealer to show techs to see if any other car had a similar set up that might be had for less than $1800 and made to work. Where do we get a cork? Lol
IMG_20230927_155224105.jpg
 

GT@50

GT Owner
Mark II Lifetime
Dec 14, 2019
937
Issaquah
I can have the O rings reproduced for about $1700. Are they worth $170 each?
 

HighHP

GT Owner
Jun 3, 2019
466
Spokane, WA
Probably - when someone needs it. But until then? I guess your question is - will anyone pay $170 to have one on hand?
 

2112

Blue/white 06'
Mark II Lifetime
I will pay that
 
  • Like
Reactions: Nafod
Probably - when someone needs it. But until then? I guess your question is - will anyone pay $170 to have one on hand?
Yes! Especially because they are likely to be unobtainium when you need one ....
 
  • Like
Reactions: Sinovac and 2112