D2 gas cap issues

[msggunny]

Anyone else have an issue getting their gas cap to seal properly when its hot outside?

Its been an issue for a couple of years now, just been too lazy to do anything about it.

Here is the issue: Fill up on a hot day, thread cap back on and twist, only goes in 1/4 way before being too hard to turn and the ratchet system on top of cap prevents me from forcing it on more. This of course doesnt allow the evap system to operate properly and code 0455 throws when it gets to 3/4 tank full.

When its cool/cold out there is no issue. It threads on just fine and seals properly.

Guess there are a few ways I can go about this, get gas in the morning or see if replacing the cap will prevent it from happening again.

 

[pinkytoe69]

I have this exact same problem.

 

[Some Dude]

My cheapfuck fix is to dip my finger in some motor oil and run it around the threads a few times. Seems to solve the binding issue on the cap.

 

[pinkytoe69]

Does anyone know the cause?

How does something get tighter with more wear?

 

[DiscoPhoto]

Pretty sure there was a recall or service bulletin on this

 

[K-rover]

I had similar issues. Ended up replacing the cap with a GM one from Autozone.. cant recall the part number.

I just had to replace the one in my Mazda after it broke in half while I was screwing it back on. Luckily the threaded piece came out with some needle nose pliers.

 

[jafir]

It makes me wonder if the PRESSURE leak detection system that the SAI trucks use is causing the caps to deform a little when really hot? I had nothing but trouble on the 03 I had. Replacing the cap seemed to only work for about 6 months and then it would get tight again. My 1999 had no issues and what appeared to be the original cap.

 

[roverMc]

Same problem, replaced it for about $10.00 from Oriellys. This one developed the same problem over time. If the damn thing didn't click it would work better.

 

[SGaynor]

Same issue - replaced it about 18 months ago with one from Advanced Auto.

Started doing it again, although I find that if I push down and turn that allieviates it (some?).

My guess is that there's a slight difference in the threads between the tank and the cap. That or the ethanol messes witht he gas cap.

Honestly I don't know.

I just taught my daughter how to make sure it's seated, and how to reset the CEL.

 

[jkempf]

Same here. The plastic distorts when hot into an oval and binds in the threads. Been meaning to take a dremel to it to clean the high spots off.

 

[kennith]

I hate those clicky things.

You can pick up a cheap replacement at any common parts store, though. I'm using one from O'Rileys at the moment. That's the solution. If yours is fucking up, just buy a new one.

I'd like to get a flip out cap, or at least a nice metal screw on unit, but I keep forgetting to do anything about it.

Cheers,

Kennith

 

[Some Dude]

That or the ethanol messes with the gas cap.

This is my guess as well. I'm not a scientist, but I did stay at a Holiday Inn Express last night.

 

[seventyfive]

Anyone else have an issue getting their gas cap to seal properly when its hot outside?

Its been an issue for a couple of years now, just been too lazy to do anything about it.

Here is the issue: Fill up on a hot day, thread cap back on and twist, only goes in 1/4 way before being too hard to turn and the ratchet system on top of cap prevents me from forcing it on more. This of course doesnt allow the evap system to operate properly and code 0455 throws when it gets to 3/4 tank full.

When its cool/cold out there is no issue. It threads on just fine and seals properly.

Guess there are a few ways I can go about this, get gas in the morning or see if replacing the cap will prevent it from happening again.

gunny,
every single cap (from the dealer) does this lately. we had one customer thinking we sell junk, so she went to the dealer. the dealer told her 'yeah they do that, just make sure the cap goes all the way down instead of listening for the click'.

take some scotch brite to the plastic threads. it barely helps, but at least it gives you piece of mind you tried something.

you should know by now quality does not mean shit with these trucks.

wait til your lr3 hits 80k miles....a gas cap is nothing.

 

[pdogg]

I bought a STANT cap a while back.. seems to work better on the disco than the auto part store generic ones ever did.. was replacing those every 6 months.

part number is 10819

 

[crown14]

Just get two new caps, rotate them out every few months.

 

[jymmiejamz]

IIRC there is a bulletin or SSM that says to file down the threads.

 

[KyleT]

Oem isn't stant anymore.

My 99 does it. Especially when it's warm out. No sai. So does the 03.

 

[msggunny]

IIRC there is a bulletin or SSM that says to file down the threads.

Im going to try that, seems like it should work.

 

[adriatic04]

i oil my threads every time i change the oil. mine has been doing it for years. between that and having to flip the clip up with my finger before closing the fuel door, filling gas is a lot of work (lot of money too).

a month or so ago I had a run of constantly overfilling and spewing gas when at the pump. i decided to park it and ride my bike everywhere.

fucker decided to leak xfcase fluid after sitting a week. it was telling me to fuck off.

 

[four]

Like jymmiejamz says, it was the peaks of the cap threads that were binding in the filler opening. After using a rough file to remove a little bit of material off the tops of the threads, the problem hasn't come back in over a year.