Fuel Filler Door - Inoperative
Article No.96-9-2
04/22/96
^ DOOR - FUEL FILLER - UNABLE TO OPEN FROM INSIDE LEVER
^ DOOR - FUEL FILLER DOOR LATCH INOPERATIVE
FORD:
1995-96 CONTOUR
LINCOLN-MERCURY:
1995-96 MYSTIQUE
This TSB is being republished in its entirety to update the Service Procedure.
ISSUE:
The fuel filler door cannot be opened using the inside lever on some vehicles. This is caused by the fuel door plunger not having enough travel to allow door to release and/or the door striker binding in the fuel filler door housing.
ACTION:
Adjust travel on fuel door latching rod to allow door to release and trim excess material that may be causing the door to bind. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
1. Open the fuel filler door using the emergency release located in the right rear area of the luggage compartment.
2. With the filler door open, fully depress the inside release handle. Check that fuel filler door latch plunger is fully retracted into the housing (Figure 1).
3. If plunger fully retracts, it is adjusted properly, proceed to Step 14.
4. If plunger does not fully retract, proceed to Step 5.
5. Disconnect the battery ground cable.
6. Remove luggage compartment door scuff plate. Refer to the 1995 Contour/Mystique Service Manual, Section 01-05.
7. Remove RH luggage compartment trim cover. Refer to the 1995 Contour/Mystique Service Manual, Section 01-05.
8. Remove power antenna, if equipped. Refer to the 1995 Contour/Mystique Service Manual, Section 15-02.
9. Release locking tab on black plastic clip portion of the fuel filler door latch rod. Unsnap fuel filler door latch rod from ball on plastic pivot assembly.
10. Fully depress the inside release handle and wedge or hold in the down position.
11. Pull fuel filler door latch rod until fuel filler door latch plunger is fully retracted. While holding the rod in this position, rotate the plastic clip clockwise until the socket lines up with the ball on the plastic pivot assembly. If there is insufficient adjustment, rod may be bent to achieve length reduction.
12. Snap clip onto ball and fasten locking tab.
13. Check operation of fuel filler release.
14. Trim 1 mm of material from the upper and lower edge of the door striker as shown in Figure 2 for a distance of 7 mm from the door inner surface.
15. Inspect for and remove all plastic flash material from the upper and lower edges of the door hinge to eliminate interference with the housing. Figure 2.
16. Using the appropriate color paint, touch up the exposed surfaces of the door striker and hinge area.
17. Use reverse procedure of Steps 5-8 to replace removed parts.
18. Confirm proper release operation when the remote release lever is held in the fully depressed position.
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 95-11-1
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
960902A Adjust Fuel Filler Door 0.5 Hr.
Release
960902B Adjust Striker Only 0.3 Hr.
960902C Adjust Fuel Filler Door 0.7 Hr.
Release And Modify Striker
DEALER CODING
CONDITION
BASIC PART NO. CODE
7028656 07
OASIS CODES: 108000, 111000, 112000, 404000