Anyone's fuel door fall off?

[xtraman122]

I forgot to post about this, happened a few weeks ago during my second fill up. I had just started pumping gas when half my fuel door randomly just fell to the ground...

Appears the door itself is comprised of two pieces, the hinged piece of plastic that actually clicks in and covers the spout, and then a flat piece of plastic that is painted the body color that snaps into it (This is what you see from the outside of the truck). The flat body colored piece is what fell off, it appears to just slide into some small clips on the hinged door and has a single little tab that secures it, just preventing it from sliding back the way it went on. Seemed like a very fragile attachment method and like it could easily just fall off again.

Haven't had any issues since, just seemed very odd when it fell off without me even touching it and the way it attached didn't instill much confidence in its ability to stay put in the future. I'll see how well it seems to be secured at my next fill-up.

Anyone else experience this? Guessing mine must not have been "clicked in" very well from the factory or something.

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[wilmaj32]

I forgot to post about this, happened a few weeks ago during my second fill up. I had just started pumping gas when half my fuel door randomly just fell to the ground...

Appears the door itself is comprised of two pieces, the hinged piece of plastic that actually clicks in and covers the spout, and then a flat piece of plastic that is painted the body color that snaps into it (This is what you see from the outside of the truck). The flat body colored piece is what fell off, it appears to just slide into some small clips on the hinged door and has a single little tab that secures it, just preventing it from sliding back the way it went on. Seemed like a very fragile attachment method and like it could easily just fall off again.

Haven't had any issues since, just seemed very odd when it fell off without me even touching it and the way it attached didn't instill much confidence in its ability to stay put in the future. I'll see how well it seems to be secured at my next fill-up.

Anyone else experience this? Guessing mine must not have been "clicked in" very well from the factory or something.

Yes, I had the same problem. I used silicone to prevent it from happening again. I applied it to the tabs and slid the fuel door back on. Crazy how easy it is to slide off isn't it? Seems like an obvious flaw with the Powerboost fuel doors.

 

[xtraman122]

Yes, I had the same problem. I used silicone to prevent it from happening again. I applied it to the tabs and slid the fuel door back on. Crazy how easy it is to slide off isn't it? Seems like an obvious flaw with the Powerboost fuel doors.

Glad to hear it’s not just me then. And yes, extremely poor design, feels like a toy.

 

[Tambow]

My door didn’t fall off but a small cover and rubber gasket on the spring loaded fill hole flap randomly fell off. Now it’s very difficult to get the gas hose into the filler hole. Also the small black plastic post that inserts into the truck to lock the door falls off sometimes. Seems they’d make an area that gets so much use Ford Tougher.

 

[Pedaldude]

https://www.f150gen14.com/forum/threads/fuel-door-cover-fell-off.3646

One place to lay the blame is on the ever tightening MPG standards and the need for cutting every ounce possible from our trucks despite how much it detracts from long term reliability.

Those capless fuel fillers are the worst thing ever, when they fail, it costs $700 in parts and labor to replace them. In my state, if your gas cap has a bad gasket and won't pass the emissions test, they give you a $5 replacement for free. Also, they claim to be siphon proof but they aren't.

 

[Daddonap]

Yes, this just happened to me. Truck 11 Months old.

 

[Lefty665]

Not much has changed. A month ago it fell off my '24 PB. You'd have figured they'd have made it a little harder to dislodge after earlier failures, guess not. Ford replaced it under warranty, parts cost would have been about $250. Silly. Guess young automotive engineers need to start somewhere.

 

[Porpoise Hork]

The Easy Fuel filler. Another example of Ford engineers designing a half-assed solution for a problem that didn't exist to make our lives easier...


I miss screw on gas caps...

 

[roadPilot]

The Easy Fuel filler. Another example of Ford engineers designing a half-assed solution for a problem that didn't exist to make our lives easier...

People often left their gas caps on the pumps. For modern vehicles, when fuel systems aren't at the correct pressure, things don't work right.

I miss screw on gas caps...

My '26 has a screw on fuel cap ... and DEF cap.

 

[FaaWrenchBndr]

The Easy Fuel filler. Another example of Ford engineers designing a half-assed solution for a problem that didn't exist to make our lives easier...


I miss screw on gas caps...

Hey, you gotta blame that shit on the EPA. It was their mandate not that a Ford.

If it hasn’t happened already in the next few years, you will see zero but gas caps

 

[Porpoise Hork]

The main reasons I can find for its adoption is are listed as convenience of use and reduction of warranty claims due to people not forgetting to actually tighten the filler caps when done refuling.

https://www.itwautomotive.com/products/refueling-recharging/class/capless-fuel-system/

Looks like the EPA did not mandate it to be used directly but this pile of crap was voluntarily adopted by many automakers in the US because it is effective at meeting the current emission regulations the EPA has in place, and lower warranty claims. Nissan for example started using it in Japan in 2016 several years before bringing it to the US market with no EPA mandate. Other brands like Hyundai/Kia still use traditional screw on caps for the vast array of vehicles they produce because they are cheaper than the capless filler necks.

https://kelch.com/resources/epacarb/
https://www.verifiedmarketreports.com/product/automotive-capless-fuel-system-market/

 

[Lefty665]

Read a couple of places it's because it needs a pressurized fuel tank. Dunno why that gets a latch on a PB but not on an EB that has similar fuel system.

 

[renzmeister]

Happens a lot apparently. Solution is to buy that little thing that pops off aftermarket.
Fuel Billet fuel door pin.

 

[Lefty665]

It's two issues. Latch breaking and fuel door cover falling off.

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