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Discussion Starter #1
I have a new 2015 350 XLT, HR, LWB, 12 pass wagon. The other day I was climbing into the driver's seat when I noticed that the fuel door was not properly closed. When I went to push it closed I noticed that the upper hinge on the right side had become dislodged from the bracket. When I attempted to push the two together, it wouldn't pop back in. Now the plastic bracket on the frame of the door is split.

Has anyone else had a problem with the door bracket breaking?

It seems to me to be a less than good engineering practice to design a plastic hinge that is not solid for such a door that is used (and abused) on a regular basis. Ford highlights that it is a security feature for accessing the fuel cap, yet it is only a plastic door held in place by 2 small pins in plastic brackets that do not even fully encircle the pin.

Thanks,
TX Aggie
 

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I accidentally opened the door when getting in once and did not notice. Someone stopped me 10 miles down the road to let me know it was open. I certainly hit speeds of 65mph before I was informed. No damage.
 

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I've caught the fuel door a few times, getting out, too. I have to be aware, lest I really damage it.
 

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Discussion Starter #7
I've run into 2 'problems' so far with the capless fill system.

1. some of the older station nozzles are bigger around than the newer ones, so it doesn't fit into the opening too well or not at all. This is usually a problem at the truck pumps.

2. I once did not insert the nozzle all the way in - stopped at the spring because I thought that it wouldn't go in completely - wrong! When I pulled the fill handle, diesel spilled all over the place. Once I pushed the nozzle all the way in, it worked fine. Biggest reason to make sure the door is closed before you refuel. Diesel in the cab and carpet would be a b*&ch to get out and the smell.

I'm bringing the wagon in for it's first oil change next week. Stopped off to talk with the sales manager about the door problem. He told me to make sure it was listed with the maintenance tech and to be sure to see him when I bring it in - it would/should be covered and fixed by them. We'll see.

I'm thinking that if I glued a little magnetic stop (like on cabinet doors) that should keep the door positively closed so that it doesn't get caught on anything getting in and out of the door. What do you think of such a fix?

Thanks
 

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Discussion Starter #8
Update on fuel filler door:

Estimated cost to remove & replace the door --- $350.00

Ford is changing the part number for this item, so it may not be available from the dealer for another week or 2 (est early Oct).

Watch getting in and out of van so you do not catch that door - could be a very expensive fix that is not covered by any warranty.
 

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Same exact thing here. I don't recall snagging it exiting the vehicle, just noticed it not closing all the way. Top plastic hinge has the little wire broken through the side of the plastic pivot point. You can't pop it back in place because the tension on the spring is too strong. This extra strong tension is what caused it to break (that and the nature of the plastic hinge).
My concern now is will a really hard rain cause water to go into the fuel tank?
 

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...

Watch getting in and out of van so you do not catch that door - could be a very expensive fix that is not covered by any warranty.
Here's my engineer's solution: I've just stopped wearing pants. Without pants, any snaggy parts are facing one of several directions away from that door.:nerd:


>:D

Stan
 

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BleenLock for Transit fuel door

Here's my non-engineer's solution, the BleenLock.

You will need a product which 3M somewhat weakly refers to as "fasteners." In fact, this is 3M's version of Velcro, and it holds together substantial additions to my Transit van, Fergus the Magic Bus. You will find 3M's "fasteners" or Velcro in several forms in distinctive black-and-yellow boxes at Home Depot: I buy the 15-foot rolls, and often economize by cutting them in half, as the hold is pretty powerful.

3M's version of Velcro uses what 3M calls "Dual Lock." There is no male and female portion: you mate identical pieces of the 3M product.

Open your fuel flap. Right behind the little pull-out tab you will see that there is a flat area at the bottom of the filler area and at the bottom of the door. Now refer to the pic to see what you should do.

Cut a rectangular portion of 3M Velcro of the correct size and then cut that rectangle diagonally. Do not remove the backing from either portion just yet. Now mate the two triangles, one on top of the other. Remove the backing from the portion that will attach to the filler area. Now press the mated portions into place (left circle on photo).

Remove the backing from the other mated portion. Now close the fuel door and press for a few moments. When you try to open the fuel door again, the two portions will come apart (I hope! - mine did), leaving one on the filler area and one on the fuel door (right circle in photo).

OK, now let the fuel door close again. Then press firmly just by the tab. You will feel a satisfying "click" as the two portions engage again. The two portions of 3M Velcro are thick enough to fill the small gap between filler area and door, so you are not straining the hinge mechanism.

Bingo! No more accidentally brushing the fuel door open when you get out of your van ....

Regards,
EJB
 

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Here's my non-engineer's solution, the BleenLock. ...

3M's version of Velcro uses what 3M calls "Dual Lock." There is no male and female portion: you mate identical pieces of the 3M product.

Open your fuel flap. Right behind the little pull-out tab you will see that there is a flat area at the bottom of the filler area and at the bottom of the door. Now refer to the pic to see what you should do.

Cut a rectangular portion of 3M Velcro of the correct size and then cut that rectangle diagonally. Do not remove the backing from either portion just yet. Now mate the two triangles, one on top of the other. Remove the backing from the portion that will attach to the filler area. Now press the mated portions into place (left circle on photo).

Remove the backing from the other mated portion. Now close the fuel door and press for a few moments. When you try to open the fuel door again, the two portions will come apart (I hope! - mine did), leaving one on the filler area and one on the fuel door (right circle in photo).

OK, now let the fuel door close again. Then press firmly just by the tab. You will feel a satisfying "click" as the two portions engage again. The two portions of 3M Velcro are thick enough to fill the small gap between filler area and door, so you are not straining the hinge mechanism.

Bingo! No more accidentally brushing the fuel door open when you get out of your van ....

Regards,
EJB
Good, maybe great idea. At first, I thought you were going to unnecessary trouble with the alignment, since the corner areas would be easy to put-one-here, put-one-there, close, and done. But, I think you're suggesting that -- unlike Velcro -- the pieces of Dual Lock material function better when they are properly aligned at installation. I think I've seen that type of stuff... like interlocking stalks.

Probably ought to clean the surfaces with alcohol, especially since they've been near fuel and air-grime. I've found that this helps when applying self-stick, "industrial strength" Velcro.
 

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Yes, that is one characteristic of the 3M version with Dual Lock - there is not an infinity of ways the two pieces mesh, so it's best to attach them to one another first.

Regards,
EJB
 

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I like ejbleens solution. I've gotten out of the van a few times just to notice the filler door is open as well. I can only assume that I'm catching it on clothing and not noticing. Can you post a pic of how it came out. I love the simple solutions to fix what should never be a problem in the first place.
 

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... 3M's version of Velcro, and it holds together substantial additions to my Transit van, Fergus the Magic Bus. ... 3M's version of Velcro uses what 3M calls "Dual Lock."
care to expound on "holds together substantial additions"? i love hearing of creative build stories, and of new uses for commonly available products. (though perhaps in a different thread, i suppose.)

paul
 

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We've only just started detailing our very modest work on Fergus, but you can find some examples of our use of 3M Dual Lock here.

Regards,
EJB
 

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We've only just started detailing our very modest work on Fergus, but you can find some examples of our use of 3M Dual Lock here.
EJB
thanks -- looks like good stuff! how heavy an item have you attached with the duallock?
 

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So far we've secured only light items. However, if you look over the various types of DualLock fasteners from 3M - say, at Home Depot - you'll find that the company specifies how much weight can be handled by such-and-such square inches of the product.

Because of our particular needs, anything that is heavy is secured to the cargo hooks. We like it for securing lighter items simply because the bond is much stronger than Velcro and doesn't move around.

Regards,
EJB
 

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I have a new 2015 350 XLT, HR, LWB, 12 pass wagon. The other day I was climbing into the driver's seat when I noticed that the fuel door was not properly closed. When I went to push it closed I noticed that the upper hinge on the right side had become dislodged from the bracket. When I attempted to push the two together, it wouldn't pop back in. Now the plastic bracket on the frame of the door is split.

Has anyone else had a problem with the door bracket breaking?

It seems to me to be a less than good engineering practice to design a plastic hinge that is not solid for such a door that is used (and abused) on a regular basis. Ford highlights that it is a security feature for accessing the fuel cap, yet it is only a plastic door held in place by 2 small pins in plastic brackets that do not even fully encircle the pin.

Thanks,
TX Aggie
Did you figure out how to fix it?
 
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