Idiots' guide to replacing the fuel flap hinge

[Viper_7]

Yes changed mine the other day, and it was a doddle following this article.

Additional advice is not to try and affix the hinge to the car when one is parked on grass. The resulting "ping" as the pin pops out and somersaults through the air into the grass was not the highlight of my day. Nor was it when it occurred again only seconds later with the next one!

Such poor design though, don't need much of a spring to keep the flap closed and what do we find, and highly sprung piece of metal held back by too small plastic tabs! bonkers!

Thanks again.

[toolbah]

There is a much cheaper and simpler fix, just replace the 2 plastic retaining lugs for the spring with small self tapping screws!!
Pre drill holes for screws with a 1mm drill bit and job done. total cost £0.00.
A far better job and it wont break again

[mmorg767]

Seemed so easy from the illustrated instructions. Found that when I attempted to punch out the four fasteners, that I met with resistance as I was completing this task. Seems like the fasteners are being pushed against metal at the other end. Hence, stopped to determine if this resistance is expected.

[Chris_Rogers]

My experience is that you require a lot of force to push the pins through enough to flex the rear wing.

If I have to do the job again I think I'll drill the pins out and refix with some stainless self tapping screws.

[Fordy]

The blue sky thinking award for the day goes to toolbah!

Originally Posted by toolbah

There is a much cheaper and simpler fix, just replace the 2 plastic retaining lugs for the spring with small self tapping screws!!
Pre drill holes for screws with a 1mm drill bit and job done. total cost £0.00.
A far better job and it wont break again

Brilliant fix, just done it. I had replaced the hinge twice now and one of the lugs had broken again. Wouldn't be too bad if I actually used the fuel flap but I'm on LPG so it hardly gets opened.

That's it sorted now

[Jotuns]

Just got my used Silver 04 S60 D5 Gtronic 50,000m fully loaded to start new career as self employed It Contractor after years of company cardom....
First fill up last night and the flap came off in my hand !

Googled it and came across your article. 5 minutes no hassle.
Brought the part from Volvo main dealer £6.56 and the friendly parts guy shared a laugh about the number of hinges they sell.....

Well done sir...

[toolbah]

Originally Posted by Jotuns

Just got my used Silver 04 S60 D5 Gtronic 50,000m fully loaded to start new career as self employed It Contractor after years of company cardom....
First fill up last night and the flap came off in my hand !

Googled it and came across your article. 5 minutes no hassle.
Brought the part from Volvo main dealer £6.56 and the friendly parts guy shared a laugh about the number of hinges they sell.....

Well done sir...

Good luck in your new career move hope it works out for you but you could have had an extra £6.56 in profit if you did my solution LOL

[TimS]

Thanks - replaced mine today. I managed to snap two of the pins, however I was able to still use them: I shaved a tiny amount off the broken end with a sharp knife, and cleaned the entry hole with the tip of a screwdriver. A pair of tweezers & a 3rd hand allowed me to hold the (very slightly tapered) pin in place, & I was able to then get it started by pressing its end with a large screwdriver. All 4 pins are now in, & sems fine.

[Symes]

Did the "Toolbah" fix this afternoon - splendid! Need to be quite accurate with drilling the pilot holes, and I found a couple of suitable screws in my electronics 'salvage bin' that were tiny enough for the job.

The flap doesn't swing open on left hand turns any more, and closes with a satisfying 'thunk' - thanks toolbah, that's saved me the price of a couple of pints!

[toolbah]

Happy to help, I love a good cheap fix and beer aint cheep these days, gotta get priority's right LOL