Remove replace fuel door?

[dgmkz]

2016 MKZ  Does anyone know how to remove the fuel door assembly? I do understand it pops in and needs to be pried out, but I need a video or hints on how exactly to pry it without damaging the surrounding paint. Thx

Edited May 26, 2023 by dgmkz

[dgmkz]

Also posted in the Gas Door thread. 

 

Answer for future readers.

On my 2016 MKZ, production date 11/15, the hinge pin does NOT look like the picture above by jmcgliss. Mine is a small diameter keyed plastic pin that presses into a plastic sleeve with blind end. So there is nothing you can put a cotter pin into. Fortunately my pin had backed out part way but was not broken. 

As far as removing the pocket assembly from the car:

1. Take out the wheel and fender liner, remove torx screw holding fuel pipe. You need the pipe loose. 

2. Cut slits where there are little marks molded into the flange of the pocket. There are 4. I only needed to cut the upper and lower rear ones. Like shown on this Edge video:

https://www.youtube.com/watch?v=NYxonwPwLks

Then pry with 2 small screwdrivers as shown in that video. Once it pops out at the back, you can use plastic pry bars like in my previous post. You may or may not crack the plastic when doing this. I cracked only one spot, not too bad and chose to reuse the pocket. This is clearly Ford's intention for removal. It's also shown in a factory manual for another Lincoln product. In that factory manual they do say it will be damaged and needs to be replaced. With care and luck you may be able to save it. I did.

3. Tape all adjacent painted surfaces so you don't scratch them. From the back side, release the large rubber surround from the  surrounding sheetmetal. Then carefully wiggle the pocket around to free it from the filler pipe and slide it out. There is barely enough room and you may have to tinker around a bit. 

4. If your hinge pin is like mine and has backed out, remove it completely by gently wiggling it as you pull it out by hand. Mark the clocking of the slot in the receiving sleeve as it's harder to see later. Then press the pin back in using a clamp. A Bessey DuoKlamp or similar one-handed clamp is ideal for this. Use it gently. Mine took a bit of force to press back in so will probably be fine for a long time. Clearly if yours is loose going in you may want to put some superglue on it or something so it doesn't back out again. 

5. Reassemble in reverse order.

 

Sorry no pictures.