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The tether on my gas cap broke, and my attempted DIY repair didn't last very long so I decided to replace the cap assembly that includes the tether. I bought the exact OEM cap on eBay from Forum sponsor Welsh Enterprises, Inc. for $21.95 delivered. Note that their price is lower on eBay than on their website. Here's the link: https://rover.ebay.com/rover/0/0/0?m...2F262669723250
Problem is that I can't get the fastener out of the end of the old tether that's attached to the fuel door. It appears to be a very small push-in plastic fastener and I've tried to pry it out with no success. Anyone know how to remove it, preferably without breaking it so I can re-use it?
I didn't look close enough at that fastener. It's just like the larger push-in fasteners for the covers in the engine compartment, only a lot smaller. There's a small indentation in the center that you push in to release the tabs while you pull straight up to remove it. Here's that fastener before and after being removed. Unfortunately, I pushed that center pin too hard and broke it.
BEFORE (BUT CENTER PIN BROKEN OUT)
AFTER - PIN REMOVED
There's a second, larger cone-shaped fastener molded into the end piece. Grab the large end firmly with needle-nose pliers and pull up hard to get it out. Here's the new cap with the tether and the old parts.
The new gas cap should come with a new plastic fastener already attached, all you need to do is push it into the hole on the door. I beleve the photo in the link you supplied shows the fastener at the end of the tether. As for the old one, you can use a trim removal tool or just use a plier and break it off since you won't need it any longer.
The new cap/tether is identical to the old one, but the small push-in fastener that I had trouble removing was not included with the new one. Both tethers have two fasteners; (1) a large, molded-in conical fastener at the end, and (2) a small, separate push-in fastener that is inserted into the hole to secure the alignment after fastener #1 has been inserted. See the above pix.
I can re-use the old small fastener, even though it's broken. If it falls out, I can get a new one.
There is no need to break anything off, as the old tether came out in one piece. I'm going to keep the old cap/tether as a spare, just in case the new cap fails. I know the old cap is good because it just passed emissions inspection, and I'm sure I can fix the broken tether.
I don't need to use my Trim Removal Tool very often but did recently when replacing the fuel filler bowl on my XK and had to switch over the cap and tether.
It removes those fasteners without damage.
Also essential for tackling Jaguar door card removal which is why I originally bought it.
If you buy a cheaper version be sure to grind the edges smooth so you don't hurt the paint when using it. More expensive ones will be ground before chrome plating. You can also put a layer of tape on the bottom to help protect the surface.
The new cap/tether is identical to the old one, but the small push-in fastener that I had trouble removing was not included with the new one. Both tethers have two fasteners; (1) a large, molded-in conical fastener at the end, and (2) a small, separate push-in fastener that is inserted into the hole to secure the alignment after fastener #1 has been inserted. See the above pix.
I can re-use the old small fastener, even though it's broken. If it falls out, I can get a new one.
There is no need to break anything off, as the old tether came out in one piece. I'm going to keep the old cap/tether as a spare, just in case the new cap fails. I know the old cap is good because it just passed emissions inspection, and I'm sure I can fix the broken tether.
Anyone ever figure out the part number or an equivalent for the pin? Need one.
Gas Cap Tether
