APPLICATION: My car is a 1996 V-6. This gas door is designed to fit a 2001 Mustang. However, after some measuring, I was convinced it would fit my '96 perfectly. I was almost right.

TOOLS REQUIRED:

A T-20 torque socket

TIME REQUIRED:

About 15 minutes.

COST OF THIS PROJECT:

The Ford Bullitt GT fuel door assembly part number 1R3Z-63405A26-AA retails for $99.95. You will also need about twenty cents worth of additional nuts and washers.

WHERE TO GET THE PARTS:

There are a number of Bullitt GT type fuel door assemblies available after-market. Some have black trim and some have a running pony embossed and some even pop open electrically. The prices range from around $100 to over $300. I liked the Ford factory door best and ordered it through my local Ford dealer.

WHY MAKE THIS MODIFICATION?

Strictly for looks.

WHAT I ACCOMPLISHED:

I like this gas door! It sets my car apart. Of course, probably not for long because I have a feeling this is going to be a very popular modification.

PHOTOS:
 

1. The stock fuel filler door.

2. The "Bullitt" GT fuel filler door assembly as purchased and with the protective film still covering it.

3. The rear side of the gas door showing the hinge and the plastic slip mounts.

4. The stock door showing the two torque-head retaining screws and the two rubber bumpers.

5. Removing the two torque-head screws that hold the stock door assembly in place.
 

6. The Bullitt GT door assembly installed. You can see that the rear of the assembly gaps just a little.

HOW I COMPLETED THE MODIFICATION:

This is a very easy modification. Start by removing the gas cap to gain some extra clearance. As a safety measure, lay a cloth across the top of the now open fuel filler pipe. Needless to say, smoking or creating a spark with the gas cap removed would not be wise.

Remove the torque-headed screws holding the gas door. There are two - one above the door hinge and one below it. The door and hinge assembly will now separate from the car.

Pull the rubber bumpers off the two additional torque-headed screws you will find under them. These screws hold the fuel opening splash panel in place and should not be removed.

Replace the gas cap. Wrap the stock gas door in something that will prevent it from being damaged and put the door, screws and rubber bumpers away for possible future use.

Carefully position the new door assembly with the slip mounts to the rear and apply slight rearward pressure to move the mounts under the lip of the gas door opening allowing the hinge of the door assembly to position properly. If you are concerned about slipping and damaging the paint, protect the edges of the fuel filler opening with masking tape.

When the door assembly is in place, slip the two torque screws through the frame of the assembly and through the lip of the gas door. Place a star washer (not provided with the door) on each screw and secure them with a nut (also not provided with the door).

Remove the protective film, polish the door and the area around it and that's it. Except, you may find the door does not fit absolutely flush at the rear. In my opinion it is not off enough to be concerning, but it is definitely not perfectly flush either. I assume this is because of a slight difference in the curvature of the 2001 quarter panel.