Discovery II Fuel Door Repair? Clip? Latch?

neuropathy

New member
Mar 20, 2019
4
0
Santa Barbara, CA
Hi Discovery drivers!

I’ve got a messed up fuel door on my DII. The plastic clip broke off - it’s not the part on the fuel door itself, but the part that that clip attaches to, on the body of the car. I can find the part that goes on the door, but not the other part, which is what I’m looking for.

Currently, the door is being latched shut by latching onto a sort of metal pole that extends from inside of the vehicle’s body, which is what the part I need was originally attached to. Each time I’ve got to fish this pole out or the door just hangs open.

See the image for a clear idea of what’s going on.

Does anyone know where I can find the missing part?

Thank you!

A413BCFC-0752-4A15-9886-CA1F408EFFF3.jpeg57F47E6B-B9E5-4925-8E77-91B75AD63DCA.jpeg
 

DEVIANT

Member
Mar 17, 2019
9
1
80111
Mine is just the metal post you set in the picture. It retracts momentarily when I hit the button on the dash. I guess if you figure it out I need one too!
 
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kennith

Well-known member
Apr 22, 2004
9,906
35
North Carolina
Mine never worked. I don't have a fuel door on there, as a result. I replaced it several times and then just gave up.

The downside is now I've got to replace the rubber that holds the filler in place.

If I ever put that door back on, I'll be using something else. I don't trust the factory release at all.

Cheers,

Kennith
 
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Blue

Well-known member
Mar 26, 2004
8,503
40
AZ
The metal post is all that should be there. Mine stopped working and all it needed was a little bending of the metal tab that holds the little black plastic clippy thing.
 
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Blue

Well-known member
Mar 26, 2004
8,503
40
AZ
When you press the dash binnacle switch the little silver metal stud retracts and presto!
 
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BarryO

Well-known member
May 15, 2018
82
3
Bend, OR
Mine is just the metal post you set in the picture. It retracts momentarily when I hit the button on the dash.
^^^ This. When I got my D2 at first the release didn't work. The problem was that the door had been bent down a tiny amount, such that the plastic part on the door didn't engage with the post. A slight tweak upward on the door fixed it.
 
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neuropathy

New member
Mar 20, 2019
4
0
Santa Barbara, CA
Hmm, I thought there was a plastic piece that was on that metal post. Something broke off at a gas station recently... I checked out part FUG100580 - I’m currently having the fish out the actuator’s pole each time since it goes back behind the car’s body. It doesn’t seem that bending the gas flap around would fix this. Maybe I’m wrong?
 

SGaynor

Well-known member
Callsign: KN4KFS
Dec 6, 2006
5,874
12
48
Bristol, TN
It looks like the grommet on your solenoid pin is gone.

Each time I’ve got to fish this pole out or the door just hangs open.
Are you saying the pin retracts back into the body? That's what I'm interpreting you as saying - when you push the binnacle button, the solenoid retracts, the pin flops around and gets hung up on the inside of the sheet metal.

If so, you need to replace the grommet - not sure if you can get the part separately (ask Will Tillery) or if you have to buy the whole solenoid part. You may be able to just buy a rubber one at Low Depot.

Like this grommet:
https://www.lowes.com/pd/Hillman-2-Pack-0-2813-in-Rubber-Grommet/4565081
 
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neuropathy

New member
Mar 20, 2019
4
0
Santa Barbara, CA
Thanks for the pictures Blue! Like SG says, it looks like the grommet is what was there. I never took too close a look at any of this before. Something rubber or plastic deteriorated and I couldn’t tell what kind of part it was, but there was definitely something on there!

It looks like the grommet on your solenoid pin is gone.

Are you saying the pin retracts back into the body? That's what I'm interpreting you as saying - when you push the binnacle button, the solenoid retracts, the pin flops around and gets hung up on the inside of the sheet metal.

If so, you need to replace the grommet - not sure if you can get the part separately (ask Will Tillery) or if you have to buy the whole solenoid part. You may be able to just buy a rubber one at Low Depot.

Like this grommet:
https://www.lowes.com/pd/Hillman-2-Pack-0-2813-in-Rubber-Grommet/4565081
Exactly - the pin retracts into the body of the car and can’t make it back out without help. Thank you - I believe this is what’s needed. Does the grommet sit all the way at the hole where the pin comes out of the bodywork? I’ll have to try to get the size of the grommet just right so it allows the pin to retract properly. From Blue’s pictures, it looks like the grommet sits around the hole of the sheet metal where the pin comes out. The grommet doesn’t seem like it grabs the pin too tightly. I’ll have to see what I can find in a hardware store and I’ll update this with what I’ve found.

pdogg - About the magnet fix, do you have to manually pull the door each time? It’s always unlocked then, I suppose.
 
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Blue

Well-known member
Mar 26, 2004
8,503
40
AZ
The little grommet is rubber with a top-hat shape to fit inside the opening with a flange around the opening. I didn't want to pry it all the way out for fear of fucking it up and then being in the same boat you're in.
 

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pdogg

Well-known member
Callsign: N2FWD
Jul 18, 2005
1,135
2
Phoenix, AZ
Thanks for the pictures Blue! Like SG says, it looks like the grommet is what was there. I never took too close a look at any of this before. Something rubber or plastic deteriorated and I couldn’t tell what kind of part it was, but there was definitely something on there!



Exactly - the pin retracts into the body of the car and can’t make it back out without help. Thank you - I believe this is what’s needed. Does the grommet sit all the way at the hole where the pin comes out of the bodywork? I’ll have to try to get the size of the grommet just right so it allows the pin to retract properly. From Blue’s pictures, it looks like the grommet sits around the hole of the sheet metal where the pin comes out. The grommet doesn’t seem like it grabs the pin too tightly. I’ll have to see what I can find in a hardware store and I’ll update this with what I’ve found.

pdogg - About the magnet fix, do you have to manually pull the door each time? It’s always unlocked then, I suppose.
yes it's always open, and I just use my finger to pry it open each time.. no big deal.. all my other cars don't have locking fuel doors either.
 
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Saturnine

Member
Jan 27, 2018
12
0
Denver
Had a similar issue -- didn't have the grommet and the whole pin / solenoid piece was pushed back into the body. Grabbed a grommet from the JY and poked the pin back through it -- been working fine ever since. I do like the magnet idea though.

 

Blue

Well-known member
Mar 26, 2004
8,503
40
AZ
I would up the ante with a push-pop magnet like on our kitchen cabinets in the 70s. Can’t beat that scrunch-scrunch sound.