Fuel cap tether - fix

[Deepseaskateboard]

Ever since owning my car, my fuel cap tether broke.

It’s a flimsy piece of plastic, which looks like it is designed to break.

Since the fuel cap still worked, I didnt want to buy a new one.
Eventually… four years later I stumbled upon this product:

https://www.ebay.co.uk/itm/402607908793

This is an inexpensive fuel tether replacement.

I can confirm it serves as a fix for the e89 fuel cap.

I removed the fuel filler cap, and inserted into a vice.

I used a 4mm drill bit in a hand powered drill to drill out the old rubber connector. It is housed in a plastic moulding on the bottom ring of the fuel filler cap, which should freely rotate. It will need a clean to have it rotate again.

Once the old plastic connector is fully removed, the new tether can be inserted through the hole into the connector housing. (Probably an elaborate term for the small piece of plastic which does this function).

Inserting this requires some force, but you don’t want a loose fit. I used a small knife to push the plastic end through the hole.

After the new tether is in, I used some epoxy putty to fill the hole in the housing, and lock the tether in place.

Epoxy putty is great for plastic repairs.

The new tether is thicker and looks more robust than the original version.

I have attached an image if the finished item.

It’s a good little fix for a common issue. Not seen it covered on here before, perhaps most people don’t have the issue or are not bothered, but it’s always annoyed me when filling up!

I hope this helps someone!

[M1k3yC]

Thanks for sharing. Mine has been broken for as long as I can remember on my E86 so I might look into fixing it now. I just assumed that it would be impossible to buy a replacement tether alone and therefore an uneconomical fix.

[Deepseaskateboard]

Thanks for sharing. Mine has been broken for as long as I can remember on my E86 so I might look into fixing it now. I just assumed that it would be impossible to buy a replacement tether alone and therefore an uneconomical fix.

Yeah, exactly. I was glad these were for sale!

[mr.tourette]

Thats a good fix and something that needs doing on mine, I'll put it on the to do list

[Pbondar]

I went with the complete unit ..

https://www.ebay.co.uk/itm/144070794399 ... 1497.l2649

And got one for my Volvo XC70 which I had also managed to break..

Not fitted either yet but assume its a bit easier than yours?

[Deepseaskateboard]

I went with the complete unit ..

https://www.ebay.co.uk/itm/144070794399 ... 1497.l2649

And got one for my Volvo XC70 which I had also managed to break..

Not fitted either yet but assume its a bit easier than yours?

Ah I see.

Prior to doing this job I didnt understand how this one fitted to the cap.

It replaces the ring, rather than just clipping over it, as I thought originally.

This is a better fix yeah, but not sure how to fit.

[R.E92]

How does the length compare vs the original?

I've tried these replacements in the past and found them all to be shorter.

You shouldn't have to do any drilling or gluing. The old one pulls out and the new one push fits in place.

[Zed Baron]

I bought a replacement strap from ebay but it turned out to be a bit shorter complained to the seller and got it for nothing

[Deepseaskateboard]

How does the length compare vs the original?

I've tried these replacements in the past and found them all to be shorter.

You shouldn't have to do any drilling or gluing. The old one pulls out and the new one push fits in place.

The length fits ok, the outer ring rotates freely, but gets gummed up.

Ill take a pic in situe.

As for drilling, I used a hand drill to carefully remove the old broken off part, it may be possible to remove this without a drill, but when I was doing this, it was part exploratory in nature.

[Deepseaskateboard]

How does the length compare vs the original?

I've tried these replacements in the past and found them all to be shorter.

You shouldn't have to do any drilling or gluing. The old one pulls out and the new one push fits in place.

Pic attached

FF57BBCE-BBF5-49A4-BBAB-D6F631335B12.jpeg (103.88 KiB) Viewed 493 times

[Probocop]

Have wondered before... what's actually the point in the tether?

[mr.tourette]

Have wondered before... what's actually the point in the tether?

to stop you dropping the cap on the floor i assume or leaving it on the roof of your car

[Probocop]

Have wondered before... what's actually the point in the tether?

to stop you dropping the cap on the floor i assume or leaving it on the roof of your car

Dropping it, I suppose a fair point. It only ever goes as far as the little holder though!

[Deepseaskateboard]

Have wondered before... what's actually the point in the tether?

Apparently misplaced fuel caps at petrol stations was ‘a thing’ enough to warrant a solution!

It sits in the little green holder.

It bothered me that it was broken!

[mr.tourette]

Have wondered before... what's actually the point in the tether?

to stop you dropping the cap on the floor i assume or leaving it on the roof of your car

Dropping it, I suppose a fair point. It only ever goes as far as the little holder though!

Nowadays yes, i remember back in the day though it always going on the roof of my car as there never used to be the wee holders..i guess at some point the belt and braces approach became more common, maybe they only put the holders in when they realised the tethers only lasted a few years