I was getting gas in NJ the other day (no self serve) and the attendant walked into the fuel door while it was open. It seemed to close OK, but the next time I went to put gas in (self serve), the fuel door fell off. There is a black "U" shaped asymetrical clip and the door itself. Since I didn't remove it myself, I have no idea how to remount it, and its difficult to see the mount. Any help?




BTW - I've got over 120K on a 2004 EX GG

Don't get me started on NJ. Apparently my request for "$20 regular" was one he'd never heard before.

Anyway, if I could just find a diagram, I would be OK. All the driver's side diagrams just show the larger panels, not the filler door.

Take a look here.....the fuel door is attached to the bracket with 4 screws.

https://www.hondapartsdeals.com/honda_parts_list.php?hp_queried_components=0&hp_series_id=2409&hp_series_model=ELEMENT&hp_series_year=2004&hp_series_door_ext_grade=5DR+EX+4WD%3BABS&hp_series_transmission=4AT&hp_series_slsareacd=KA&hp_system=H&hp_component=B++4920

Take a look here.....the fuel door is attached to the bracket with 4 screws.

https://www.hondapartsdeals.com/honda_parts_list.php?hp_queried_components=0&hp_series_id=2409&hp_series_model=ELEMENT&hp_series_year=2004&hp_series_door_ext_grade=5DR+EX+4WD%3BABS&hp_series_transmission=4AT&hp_series_slsareacd=KA&hp_system=H&hp_component=B++4920

It's not just the plastic part, the whole assembly popped off. There is a metal bracket attached to the inner part of the quarter panel that the fuel door hinges on with the help of the "u" clip. The only way I can see to put it on is by feel and my few tries failed. I'm also not sure if something broke or it simple popped off.

It's not just the plastic part, the whole assembly popped off. There is a metal bracket attached to the inner part of the quarter panel that the fuel door hinges on with the help of the "u" clip. The only way I can see to put it on is by feel and my few tries failed. I'm also not sure if something broke or it simple popped off.

I had to take mine off on my old E when i changed the cladding.Its attached to the body with two bolts.

It's not just the plastic part, the whole assembly popped off. There is a metal bracket attached to the inner part of the quarter panel that the fuel door hinges on with the help of the "u" clip. The only way I can see to put it on is by feel and my few tries failed. I'm also not sure if something broke or it simple popped off.


I took another look at mine this morning......the piece the door hinges on is attched to the body with 2 bolts....it has to be replaced as an assembly if anything breaks.

I was about to fill up my E, and when I opened the fuel door the hinge broke. I was wondering if anyone could help me with a part number for the hinge. I was looking on Majestic Honda and South Bay Honda's sites with no luck. Thanks in advance for any help.

It looks like it might be
63910-SCV-A01ZZ item 16 STIFFENER, FUEL FILLER $ 47.03

at Majestic Honda Look under
System Name\Component "OUTER PANEL-ROOF PANEL"

:)

I think you are correct. Thanks for the help.

Experienced a similar situation. I had mine break off at the gas station recently. The two spot welds on the hinge broke but I was able to have the welded back by a friend. Looked funny without the door for a few days:-D

Or you can have the door spot welded back on.

Unscrew the 2 bolts securing the bracket to the car, then remove the bracket. Do a test fit to see how it goes together. You should be able to see how the door was held to the bracket by a pin that had been spot welded at the factory. Prior to doing the repair, remove the plastic cover from the door assy - otherwise the plastic might get inadvertently melted. After doing the repair, it might be a good idea to lubricate the pivot points.

My wife's is currently broken, so I had a chance to take a look at it.
The door was completely broken off, so I removed the bracket that was bolted to the car (2 bolts - 10mm socket). There's a thin rod that fits thru the door hinge & the ends of the rod are tack welded to the bracket - the welds are kinda puny. I'd guess that the door hinge binds on the rod, weakening it until the welds break. So....

If your Element fuel door is functioning properly, I suggest removing it & lubricating the hinge before it has a chance to break.

The fuel filler door pin can be rewelded to the bracket.

My wife's is currently broken, so I had a chance to take a look at it.
The door was completely broken off, so I removed the bracket that was bolted to the car (2 bolts - 10mm socket). There's a thin pin that fits thru the door hinge & the ends of the pin are tack welded to the bracket - the welds are kinda puny. I'd guess that the door hinge binds on the pin, weakening the welds until they break.

For those whose fuel door is functioning properly, I suggest removing it & lubricating the hinge before it has a chance to break.

Mine broke this week. The ends rusted and failed where the hinge pin is welded to another piece.

Hinge on junkyard replacement looks pretty good:
http://www.skidmore.edu/~pdwyer/e/eoc/fuel_door_hinge01.gif

The old one (other end was similar):
http://www.skidmore.edu/~pdwyer/e/eoc/fuel_door_hinge02.gif

This looks like a very weak and vulnerable piece, so inspect and lubricate. You will have to take the assembly off the car to do this, but it's held on by two easily accessible bolts (10mm heads).

The assembly is called "stiffener, fuel filler," Honda part #63910-SCV-A01ZZ, $48 retail.

Thanks rambler. I'll have to take a look at mine.

This broke on mine within a couple days of me buying it used. The part new from the dealer cost me about $35 I think.

broke mine when i tried to bend the door a little bit so it would center in the cutout for the gas tank hole... i was super bummed. BUT my nephew just added a little piece of round stock and welded 'er up for me! i was really worried the part would be super expensive, but ended up costing me nuthn'

hooray for great nephews!

After 104k mine came off in my hands at the gas pump a few weeks ago. Same issue. Thanks for the heads up.

I got same issue, my fuel door fell-off at the gas station. I was researching the structure of this assembly, and I saw this forum with pictures (thank you for all pics) I inspected the inisde of the fuel door assembly, and found 2 bolts (10mm) which releases the entire fuel door assembly unit. I had exactly same as your broken peice, very rusted. Over all, it looks very weak piece of metal. Honda should recall this door assembly. Thank you again for nice pictures.

Thanks for the heads-up! We had a surprisingly similar issue on our Miata, which I fortunately caught before it rusted to breaking. That would've been an ugly situation because of the cable release.

A spritz of WD40 on the hinge might be in order. I'll go do that before I forget.

It took about 10 minutes to replace the whole thing. Pretty easy.

I took a close look at the hinge pin and weld. There wasn't a speck of rust anywhere on mine, and no evidence of the hinge binding. The paint coat was unbroken down to the end of the pin. The break was clean.

The pin failed from metal fatigue. The combination of the abrupt shape change adjacent to the welding tab plus the heat of the impulse welding weakened the metal. If the pin had been made of a different alloy, larger in diameter, offset more smoothly and/or formed at a right angle to pass through the plate and welded on the other face, it probably wouldn't have failed.

Considering the number of 2004 models that have had this problem, I think that it is a design/QC issue.

My wife's Element (2004 ~60k) has the same issue. Started getting wobbly, then just detached yesterday at the gas station. I didn't see any signs of rust on the pin, but have not removed the assembly as of yet for closer inspection. I will most likely remove and try to re-weld. Thanks for the pics and info - looks like Honda dropped the ball with this part!

*Edit: Hey! First post...hi everyone!

Rather than trying to re-weld the pin I made a "bridge" from 1/8' copper coated rod, ran the ends through drilled holes to the other face, and bent them over. The bridge has a curved span to press the broken pin firmly against where it snapped off. I covered both faces of the patched area with metal mend epoxy. The bottom photo shows the back face after the first coat of epoxy.

anyone have a used one, or a lead on where to get one cheap?
I am in toronto, but could get it from anywhere.
Dealer wants $65 for the part new...!

mine snapped off while at the gas station on my 2004 ele.

Thanks!

justin

Junkyard

Threads merged.

I have 83, 000 Miles on my 2004 Element and the other day the fuel door stripped right off the hinges...I jumped on here, and sure enough there were solutions and pictures to help. I found someone to weld everything back together for $15....Just want to thank the ELEMENTOWNERSCLUB for all your help. :grin:

As the title says, my gas lid (not the lid for the tank) has fallen off. At first the spring that keeps if shut popped out which wasnt a bad problem it was just loosely hanging there. Now the entire thing just falls out.. is there any way to get replacement parts for it? My element just looks stupid riding down the road with the gas lid hanging to the side basically almost falling off. I could use a replacement if possible! so if anyone has any info about it please let me know!
~Thanks!

As the title says, my gas lid (not the lid for the tank) has fallen off. At first the spring that keeps if shut popped out which wasnt a bad problem it was just loosely hanging there. Now the entire thing just falls out.. is there any way to get replacement parts for it? My element just looks stupid riding down the road with the gas lid hanging to the side basically almost falling off. I could use a replacement if possible! so if anyone has any info about it please let me know!
~Thanks!

Moved your thread into here. You should find your answer in here.

Thanks everyone. Same problem here. Hinge pin snapped off from fatigue, not rust.

Hmmm, who do I know that welds?

Seems like a horrible design. Just a bit more metal and none of us would have this problem.

> Just a bit more metal and none of us would have this problem.
Agreed. Honda saved half a cent on the part, and cost us $20–$50.