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Disco 2 Fuel Door clip install

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Old Feb 22, 2014 | 05:08 PM
  #1  
Sykman's Avatar
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4wd Low
Joined: Dec 2012
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Default Disco 2 Fuel Door clip install

Ok, broke off the first one of these I bought so took my time on the second one and got it in. Here's what I did for anyone else needed to replace this cheap little clip.

1) First thing I did was soak the new clip in boiling water for a few minutes. This was all that was needed to get this clip just a little more pliable.


2) Start by inserting the rectangular clips little tang into the rectangular slot but make sure you have the circle clip tab pointing straight up. It might take a little bit of wiggling and pressure, but this is why you heat the piece up a little first.

3) Once the rectangular clip is in completely, you can rotate the entire clip clockwise until the round clip lines up with the round hole. Once lined up, just push the round clip in.

4) Final step is to make sure the metal bracket is as close to the plunger pin as possible. All that is needed is some slight pressure to bend this tab into the correct position.

5) Enjoy - until this cheap crappy designed piece breaks again.
 
Attached Thumbnails Disco 2 Fuel Door clip install-photo-1.jpg   Disco 2 Fuel Door clip install-photo-3.jpg   Disco 2 Fuel Door clip install-photo-4.jpg   Disco 2 Fuel Door clip install-photo-5.jpg  
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Old Dec 20, 2017 | 03:06 PM
  #2  
Steve8829's Avatar
1st Gear
Joined: Dec 2017
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Default Fuel door

Thank you for this informtion. I followed your steps..it worked perfectly.
 
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Old Dec 21, 2017 | 12:31 AM
  #3  
Lisa Bunch's Avatar
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Joined: May 2014
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From: Apache Junction, AZ
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I'm using a speaker magnet to keep my door shut...
 
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Old Jun 2, 2018 | 05:59 PM
  #4  
Disco_Ky's Avatar
1st Gear
Joined: Jun 2018
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From: Colorado
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Sorry to revive the old thread but I recently replaced the clip and upon installation it simply flips down toward the ground and the peg, therefore, routes up above the correct channel.

As an interim solution I've simply been using my knife to push the clip into the correct position right before closing. But any insight into how to remedy this would be greatly appreciated.
 
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Old Jun 2, 2018 | 09:03 PM
  #5  
Twix's Avatar
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Joined: Jul 2015
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From: Calgary, AB
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I just bent the metal tab slightly to keep the plastic clip where it should be
 
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Old Jun 2, 2018 | 09:36 PM
  #6  
Friday Night Disco's Avatar
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Joined: Dec 2016
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From: Fall City, WA
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Originally Posted by Twix
I just bent the metal tab slightly to keep the plastic clip where it should be
same here, I had to bend a couple times to get the right angle
 
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Old Jun 4, 2018 | 02:54 AM
  #7  
shanechevelle's Avatar
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Joined: Oct 2011
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From: NE PA
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I paid $8 at the dealer. Bought 2 in case it happens again.
 
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Old Nov 4, 2018 | 05:33 AM
  #8  
Jim Richardson's Avatar
1st Gear
Joined: Nov 2018
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Default Thanks

Thanks for the great tutorial and photos. I've now got a fuel flap that works and looks miles better. Cheers
 
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