Fuel Filler Door - Inoperative

90ford08

Article No. 90-8-4

^ DOOR - FUEL FILLER - BROKEN PLUNGER - NEW SERVICE PROCEDURE

^ DOOR - FUEL FILLER DOOR LATCH INOPERATIVE

FORD: 1989-90 TAURUS

LINCOLN-MERCURY: 1989-90 SABLE

Figure 1:

ISSUE: An inoperative fuel filler door may be caused by a broken plunger in the latch assembly. The broken plunger can now be serviced without replacing the entire latch assembly.

ACTION: Install a new fuel filler door latch plunger. Refer to the following procedure for service details.

1. Open the fuel filler door.

2. Remove the lock nut from the threaded sleeve that holds the end of the cable to the body, Figure 1.

Figure 2:

3. Remove the cable end from the fuel filler housing. Bring it into the luggage compartment for servicing, Figure 2.

4. Separate the return spring housing from the conduit end by depressing the conduit end retaining prongs, Figure 2.

5. After disconnecting the return spring housing, remove the manual override strand from the plunger.

6. Push the manual override strand through the plunger and lift it out of the slot, Figure 3.

Figure 3:

7. Remove the inner strand from the plunger by sliding it sideways out of the slot, Figure 3.

8. Obtain a new fuel filler door latch plunger (FODZ-5428610-B). Hook the manual override strand and the inner strand to the new plunger. (Reverse Steps 5, 6 and 7.)

9. Route the manual override strand through the slot of the conduit end.

10. Snap the return spring housing onto the conduit end, Figure 3.

NOTE: MAKE SURE THAT THE ANGLED END OF THE PLUNGER IS NOT REVERSED IN POSITION. THE ANGLED END MUST FACE DIRECTLY TO THE RETAINER ON THE DOOR OR FACE OUTBOARD OF THE VEHICLE.

11. Place the cable end back into the fuel filler housing. Secure it with a lock nut. Tighten the nut to 2.5-4.5 lb.ft. (3.4 - 6.1 N-m).

12. Close the fuel filler opening door assembly. Cycle the remote fuel filler door latch assembly and check for proper operation.

PART NUMBER PART NAME CLASS

FODZ-5428610-B Fuel Filler Door Plunger B

OTHER APPLICABLE ARTICLES: None
WARRANTY STATUS: Eligible Under Basic Warranty Coverage
OPERATION DESCRIPTION TIME
900804A Install Plunger 0.3 Hr.
DEALER CODING
BASIC PART NO. CONDITION CODE
7405CO6 42
OASIS CODES: 1200, 4500