Ford Transit Fuel Door Replacement

The fuel door on our 2021 Ford Transit broke. Unfortunately, it’s held together by a flimsy plastic piece, which makes it prone to damage.

When I took the van in for a routine service at the Ford dealership, I asked for a quote to fix the fuel door. They quoted me over $600, which included the cost of the door and painting it to match the van. Needless to say, I decided not to get it fixed there.

Later, I did some research online and found that replacement fuel doors could be purchased for around $50. I also came across an excellent video tutorial on YouTube Ford Transit Fuel Door Replacement – YouTube that showed exactly how to replace it.

Parts and Tools Needed

Transit Fuel Door, Transit Gas Door Assembly + Black Cover – The door assembly with cover.

Replacement Molding Clip Retainer – Replacement clips in case I broke any (I didn’t)

Tresalto Auto Trim Removal Tool Kit – Tool to remove panels

T25 Wrench – I already had one of these.

Here is what the door looked like:

The tools used:

Using the tools, I first unscrewed the T25 Torx screws holding the fuel door and surrounding panels in place. Then, I carefully used the trim removal tools to pop the panels off. The process was straightforward, and none of the clips broke during removal.

I positioned the new fuel door assembly in place, secured it with the Torx screws, and snapped the panels back on. It was a seamless fit, and everything went back together smoothly.

And screwed it in and snapped the panels back into place. The final result:

For those who prefer a seamless look, it’s possible to transfer the painted panel from the old fuel door to the new one. However, I liked the sleek black look of the replacement door and decided to keep it as is. I saved the painted panel in case I change my mind in the future.

The entire replacement process took just 10 minutes. By doing the repair myself, I saved over $550 compared to the dealership’s quote. If you’re dealing with a broken Ford Transit fuel door, I highly recommend tackling this repair yourself. It’s quick, easy, and cost-effective.