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DIY: Gas Door hinge permanant fix w/pics

Help, Advice, Owners' Discussion and DIY Tutorials on Volvo's stylish, distinctive P2 platform cars sold as model years 2001-2007 (North American market year designations).

2001 - 2007 V70
2001 - 2004 V70 XC (Cross Country)
2004 - 2007 XC70 (Cross Country)
2001 - 2009 S60
2003 - 2007 S60 R
2004 - 2007 V70 R

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98T5
Posts: 320
Joined: 11 August 2007
Year and Model: V70T5,98' / 940,93'
Location: Texas

DIY: Gas Door hinge permanant fix w/pics

Post by 98T5 »

So I had the fatal lost gas door happen to me and got highly p'ssd about it. So I sat and figured a way to fix this thing permanently. My entire assembly fell off, even the hinge. So I hit the junkyard and found one on an 850 that was more than happy to be a donor for my car.

All you need is:

1. Two 3/8 male-female screw sets
2. Epoxy Steel Stik
3. A wide screw that can be used to score out the inside of the bracket holes to make wider
4. Sandpaper

First, clean up the area with some BrakeKleen, Second, Scuff up the holes with sandpaper, Third, insert the female screw with some Steel Stik on it and pack it in good, the lip on the screw keeps it from falling into the hole so don't worry just packed it in tight. Fourth, Gouge out the holes on the bracket with a wide screw, Then you can allow the car to sit 30mins(what I did), or you can use a heat gun or hot blow drier to speed up the process. Once the female screws are set in the Epoxy, you can thread the new screw thru the wider holes on the bracket (I only used 2 of the holes, the outer ones, didn't seem to need the inner ones it worked so well). Gently screw the screws in handtight, no need for brute force. Let it set overnight and by morning your door should be holding up stronger than from the factory. G'luck!!
Epoxy Steel Stik.JPG
3.8 male female screw set Lowes.jpg
3.8 male female screw set Lowes.jpg (149.39 KiB) Viewed 872 times
Female inserted and packed with Epoxy.JPG
Female inserted and packed with Epoxy.JPG (230.38 KiB) Viewed 872 times
Strip out wider holes on old brace.JPG
Allow Epoxy to set up at least 30 minutes.JPG
Allow Epoxy to set up at least 30 minutes.JPG (250.45 KiB) Viewed 872 times
Fit  male screws thru wider holes.JPG
Pack more Epoxy around for piece of mind.JPG
ALL DONE PERMANTLY! :mrgreen: :mrgreen:
ALL DONE PERMANTLY!!
ALL DONE PERMANTLY!!
T
98’ S70 T5 Turbo Manual - Midnight
01' S60 T5 Turbo- Brandy
98' V70 T5 Turbo - Swifty
93’ 244 n/a - Mr.Chill
91' 940 SE Turbo - Mojo SOLD
83' 242 DL - Bluto SOLD
93' 940 Wagon - Django - SOLD
:mrgreen: 8) :mrgreen:

slione
Posts: 23
Joined: 19 November 2012
Year and Model: XC70 2002
Location: New Jersey

Post by slione »

Well done! 8)
____________________________
02 Volvo XC70, 174,000+ mi
09 Honda Pilot
74 VW Super Beetle Convertible

98T5
Posts: 320
Joined: 11 August 2007
Year and Model: V70T5,98' / 940,93'
Location: Texas

Post by 98T5 »

The bean counters at Volvo should be ashamed of themselves for skimping on this little detail. :roll:
98’ S70 T5 Turbo Manual - Midnight
01' S60 T5 Turbo- Brandy
98' V70 T5 Turbo - Swifty
93’ 244 n/a - Mr.Chill
91' 940 SE Turbo - Mojo SOLD
83' 242 DL - Bluto SOLD
93' 940 Wagon - Django - SOLD
:mrgreen: 8) :mrgreen:

jimmy57
Posts: 6694
Joined: 12 November 2010
Year and Model: 2004 V70R GT, et al
Location: Ponder Texas
Has thanked: 4 times
Been thanked: 320 times

Post by jimmy57 »

The ones I replace always are broken where the lid part attaches to the body part. I have only seen one that fell off the body from body attachment failure. In the Sunbelt the plastic fails there first. I have no idea where you are (no profile info).

98T5
Posts: 320
Joined: 11 August 2007
Year and Model: V70T5,98' / 940,93'
Location: Texas

Post by 98T5 »

jimmy57 wrote:The ones I replace always are broken where the lid part attaches to the body part. I have only seen one that fell off the body from body attachment failure. In the Sunbelt the plastic fails there first. I have no idea where you are (no profile info).
I'm in Texas. and mine failed from continuously slamming the door while the clip part was already broken. just decided to fall off from the plastic rivet points I guess.
98’ S70 T5 Turbo Manual - Midnight
01' S60 T5 Turbo- Brandy
98' V70 T5 Turbo - Swifty
93’ 244 n/a - Mr.Chill
91' 940 SE Turbo - Mojo SOLD
83' 242 DL - Bluto SOLD
93' 940 Wagon - Django - SOLD
:mrgreen: 8) :mrgreen:

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