'96 Explorer fuel filler cap binds up.

[Jim_WY]

I tried to use the search function just now, but it doesn't work at the moment. Then I tried to drill into Explorerforums from the outside with Google, and that didn't come up with any threads about the exact problem I'm having so...

On my '96 Explorer, the fuel filler cap tends to stick and bind. It's hard plastic against what must be somewhat rough steel threads. This has gotten worse and worse. I don't want the cap to break off at some point, so I'm wondering if anyone else has had this problem, and if so, what they've been able to do to lube it up or smooth things so the cap will go on and come off without using what seems like very excessive force.

I did put some silicone grease on it, and that lasted for a few months. Now it's sticking again. I could put more of the same grease on it, but I wonder if anyone has a more permanent fix for this.

Heck, maybe just replace the filler cap?

Sorry if this has already been covered, but as I said, the search isn't working right now, and drilling in from the outside didn't show any similar problems.

Thanks, everyone!

 

[koda2000]

I say, just replace the fuel cap. If the filler neck is rusty, stick a damp rag in the opening (to catch and debris) and wet sand the mating surface with fine wet/dry sand paper (wet). I'd suggest replacing the filler neck too, but '96 filler necks are hard to find.

 

[Jim_WY]

Thanks!

I got a replacement gas cap, and it seems to fit better. It's as if the diameter with the threads on the original gas cap is swollen up and too large to comfortably fit into the filler neck. It's actually quite hard to even start the cap into the neck. The cap is too fat to fit into the neck tube. This has been coming on gradually over the last few years.

The neck itself looks shiny and nice. No rust or obvious roughness to it. It's really all quite bizarre unless the plastic of the filler cap, over time, absorbs gas fumes and really does swell up, making it extremely tight.

Replacing the cap is a quick, easy fix.