Volvo S60 » Fuel Door Repair Kit

How does everyone justify giving this item more than a one star review (it showed up) when everyone also mentions that the pins break off with any attempt to tap them ever-so-gently in?
After ALL FOUR pins broke off, I bought common, coated finish nails of an equal diameter, clipped them to a length about equal to the full length of the broken off pins and tapped them in (ultimately pushing the remaining pin stubs completely through).
Seriously, don't have any faith in being able to install this item as received w/o having a backup plan of your own.

I just completed the installation of the fuel door hinge on my 2003 XC70. Try as you like, but the little plastic pins will not budge (see other reviews). Having read the reviews before I purchased this and confirming for myself that the pins will not move, I immediately broke off all four of them and had some short screws on hand to attach the new hinge. The removal of the old hinge and replacement with the new one took maybe 10-15 minutes. IPD should consider updating the instructions and/or providing the screws with the kit since it doesn't work as advertised. No big deal though.

First off every pin broke off of the first one that iPd sent me. So the next day I called them up and they gladly sent me another. (Rating of 5 for Customer Service) Once the new one came I was pumped, but yet again some pins broke. After reading other reviews I realize that I am not the only one with this issue, but I did as the others did and drilled it in place. Holds perfectly now and may even be sturdier. Thanks again iPd for the wonderful customer service.

Oct. 2008 - I would have rated the kit higher if not for my problem with the pins and the instructions. After rather easily tapping the previous pins out-the problem came tapping the new pins into place. My piece came with the pins molded as if they were ready to be tapped in. Was this an improved version due to others problems? No, after positioning the piece I was unable to drive the pins in. I sheared off the first pin. I figured out the piece was molded like that with no holes drilled for pin insertion. With a needle nosed pliers I snapped off the remaining pins, used a small chisel to smooth the surface and a 1/8" drill to actually drill holes to insert the pins. Actually I used a no. 10 metal screw on the outer most top and bottom holes to hold the piece (I was unable to use them on the innermost holes because the heads were too large - and like most projects, by the time I started this all the stores were closed!). Once the piece was held firmly in place by the screws, I was able to drive the two best remaining pins in. This part could be made a lot easier to install by molding the holes in the piece and molding the pins separately but designed to be cut off . It would have holes-the pins would be sized for the holes and they would have sufficient length. I'd suggest going to the hardware store and purchasing small headed screws if I were to do this again. Positives are the part fit the door well, I fixed the fuel door and the cost was reasonable.

This product is great for replacing a broken fuel door and the directions are by far the
easiest I have ever read. However something should be done about the pins that
need to be hammered in. When I went to tap them into place they wouldn't budge to
save my life and ended up breaking off two of them but was able to use small metal
screws instead.

Awesome product. Very handy due to being able to break easy. The pins come attached on four dots. You are required to brake the pin off first then put it into the hole and then gently hammer them in. I used needle nosed pliers (due to the small size of the pins) to place the pin into the hole. Then using the nose of the pliers, I just gentle pushed until the pin was even with the surface. Will take about 20-30 min to install because it is kind of hard to attach the lid to the hinge. Instructions are very clear and easy to understand.

I am fairly mechanical and I found this to be very simple and easy to install, except for when it came time to tap the new pins in. I found it impossible. perhaps mine was defective, but I could not get any of the pins in they all broke off. I ended up drilling holes where they broke off and I used short metal screws about the same size as the pins. This seemed to work real well and feels very secure. I think that part of the repair kit could be improved.

Timing of release of the fuel door repair kit by IPD was perfect. My fuel door would open a freeway speeds and since it didn't close all the way, the fuel door locking device broke.

Installation was very easy and the instructions are clear. Took me about 25 minutes from time of rounding the tools to putting them away. The only reason I didn't rate it a 5 was that two of the small pins flew out of the hole when hit with the hole punch; I ended up using needle nose pliers to push them further in before using the hole punch and small hammer.

Thanks IPD