Gas cap wont come off

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Steve Mcbean said:
Wont even give pushing it in. Like its being sucked in by lots of pressure agaisnt the gasket. Someone else here mentioned there sgould be no pressure since i drove it days ago, but i ran it in the garage yesterday. Gonna try some other stuf some of you guys mentioned for tomorrow since its late now. I'll let u guys know how it went. Hopefully i dont create spark when i use my gas powered grinder on it...Lol...
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This is not a pressure problem this is a devise that is not right for its application, it’s locked up and that’s that .
 
Spray the crap out of it with WD like I suggested earlier , spray it directly into the key hole as well
 
I am assuming that your cap is lime this
Screenshot_20220103-220113.png


The black plastic pins have to retract to allow the cap to come off.
Most likely of you remove (drill/ slide hammer)the cylinder you will be able to access the mechanisms
 
I just saw you added some pics of the custom made fuel filler and door- those ain't Demon parts, so who knows what filler neck is on there or whether the vent was retained... it's probably a matter of mismatched parts that jammed up, such as a Mopar cap on a who-knows-what filler neck.
 
Professor Fate said:
Just trying to wrap my head around this- first, how your tank could develop enough "pressure" to lock your cap in place; the tank is vented, and even if the vent(s) plugged, you'd get vacuum, not pressure. Look at your tank, that kind of vacuum would be collapsing your tank.
If you did somehow get the tank pressurized to the point of not being able to remove the cap, it would be pushing fuel right out the carb vents and flooding everything out. And the pressure would not persist for days afterward.
It has to be a mechanical issue- the locking pawls are not releasing as the key is turned.
Get some penetrant sprayed into the lock, and behind the cap if possible. Keep working the key and the cap back and forth and you might get it to pop loose. Be patient and persistent. If not, you'll have to drill it out as others have described. Then get yourself a good standard cap.
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Makes sense. Will keep at it tmrw.
 
Glenn’s HC said:
This is not a pressure problem this is a devise that is not right for its application, it’s locked up and that’s that .
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Yup, i think the cap is wrong for the car. Its brand new. Wd40 inside the key hole? I assume to lube the gasket, cuz the key easily turns.
 
Honestly Steve, I think it's in your best interest to get that cap off of course, and convert it back to stock in the fuel filler area. I believe you will find that will work much better for you.
 
Once it’s off I wouldn’t bother putting a locking cap back on if this is not a daily driver that sits in a parking lot why worry about anybody tampering with your fuel tank If you have to worry about leaving your car while you walk around at your cars and coffee Cruzan then that’s pretty bad
 
I'm not sure if it would help or not, as it's a little hard to discern from the photos of the cap. Would a H-U-G-E set of Channellocks be able to grab the outer rim of the cap? I have a pair that is about 24" long and the jaws will open up easily to 3" or more.
 
It's been misaligned as it was forced in.
The caps body has 2 protruding alignment slots... I think they are what jammed into the filler neck .

Slide hammer it off. Use the screw end and have to just destroy the cap lock...but that's about all that will remove it.
You will find if you pull on the outside enough...that the outer plate will come off leaving the raw aluminum body portion.
You just want to unseize the jammed portion then the lock should turn and it will come off like normal.
 
WAIT!!! You never have to drill into a gas tank........just use a center punch with a medium sized hammer, especially a smaller one. It will easily pierce the tank with no spark and no metal shavings. Then simply sand the area and use some gas tank sealer putty from auto zone to seal the hole. I've used this method lots of times, works like a charm!!!:thumbsup::thumbsup::thumbsup::thumbsup:

I can post pics of the punches I'm talking about if you like??
 
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Had to remove more than a few of these things in my days working in gas stations in Winterpeg winters, or whenever I bought a car from a salvage auction that didn't have the key for the damned gas cap. Typically I used a hammer and a large flat screwdriver to drive into the lock mechanism and destroy it. Then a simple twist would usually get them out. Sense of satisfaction every time. :)
 
Treblig said:
WAIT!!! You never have to drill into a gas tank........just use a center punch with a medium sized hammer, especially a smaller one. It will easily pierce the tank with no spark and no metal shavings. Then simply sand the area and use some gas tank sealer putty from auto zone to seal the hole
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Why in the world would you need to do that?
 
Glenn’s HC said:
Also tap around it on the face of the cap with a small hammer
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As Glenn said but I'd take a wood block and and hammer around the cap to make sure the palls are past the relief. Hit it pretty good to be sure it's straight on then try the key to remove it. You should be able to feel the palls moving with a little resistance when you turn the key. If you try all the non destructive methods first with no luck then it's time to gut that sucker. Good luck.
 
All... Post #1 and Post #3 the OP states "the key turns"

The issue is the key is not retracting the pins that lock the cap on.

Why is the million dollar question?
 
Treblig said:
You don't normally. But the OP wanted to take some of the pressure out of the tank....didn't you read the previous posts
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Yes I read and I posted (post 14) about why the tank could not have pressure or vacuume in it. the tank is not pressurized or has a vacuum in it. That was the OPs thought as to what it felt like. And simply removing the supply tube at the sender would have released any and all pressure /vacuume with out doing any harm.
 
Dana67Dart said:
Yes I read and I posted (post 14) about why the tank could not have pressure or vacuume in it. the tank is not pressurized or has a vacuum in it. That was the OPs thought as to what it felt like. And simply removing the supply tube at the sender would have released any and all pressure /vacuume with out doing any harm.
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I agree with what you wrote...............but if the Op is determined to put a hole in the tank I wanted to give him the safest way. Neither you or i know what he will do in the end???
 
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