Fuel Door Repair Kit

After reading some of these previous reviews, I decided from the very start that I was not going to take a chance on possibly bending or messing up these little pins by trying to tap them in from their supplied post position. So I brought the new hinge to my work bench and used my fingers to break off all 4 pins. Then I used my mini file to take off the rough edges around the ends of each pin and gave them a tiny taper at the end for an easy start into the holes. Then I simply pushed these same pins into each hole about 1/8" deep. Then I assembled the hinge, pin and door together at my bench and two minutes after that I was easily tapping the complete assembly onto the car without any issues whatsoever. As far as I'm concerned you have to start these bad-boy pins into the holes ahead of time at your bench or you'll be inviting trouble on yourself.

Took about 10 min. to install. first punch out old pins to remove old hinge. next i had to pretty much break off old hinge off fuel door to remove it. then i snapped new hinge onto the fuel door, next i did exactly what the instructions said use oversized punch to knock in new pins flush. Whatever they bend so easy and then break off. no problem i just snapped off the rest of them, took hinge/fuel door to work bench busted out 9/64 drill bit. and just barley drilled enough so the pins would seat, took hinge/fuel door back to the car. and used oversized punch to knock in new pins flush, worked perfect...

This was my first time using IPD but I have to say, I'm really impressed with them.
The item was easy to find, the order was processed faster than I could have
expected and the install was pretty good, too. I read a couple of reviews that
mentioned the pins breaking off, so I paid close attention to the directions as I
went. I used a piece of the cardboard box to protect the edge of the fuel door and
used channel locks to snap the hinge onto the door; worked like a charm. I used a
punch to knock out the old hinge pins and the hinge came off easily. I saved one of
the pins that didn't fall inside the quarter panel, just in case. I had my wife hold the
assembled fuel door in place while I carefully tapped the pins on the new hinge into
place. I had no problem with the first two (top and bottom) but the two in the
middle bent and fell off as I tried to tap them in. I picked them up and went into
the house to think. As I looked at them, I realized they were the same size as the
old one I'd picked up and it dawned on me that they didn't break, they just fell out
of their holes. Trying to push them back in was futile but, after a bit more thinking
("Think like a Swede", I told myself) I set one in a vice grip, laid the edge on my
work bench and filed the tip with a rasp. I took it back out to the car, still in the vice
grip, and twisted it back into the hole. With a little careful tapping I had it set in 30
seconds. I did the same for the other one, installed the spring and the door was as
good as new! Thanks, IPD. That repair would have cost me a couple of hundred
bucks at a body shop.

I just finished installing this on my 02 s60. Was pretty easy. Make sure when your tapping the pins in...keep them straight. I tapped the top and bottom ones in first no problems. The middle 2 were a little more frustrating. Both of them came off. I simply held them with needle-nose pliers tapped the pliers with a SMALL hammer to get them started and just finished tapping them in from there. Install time with frustrations around 15 mins. One more thing...Attach the hinge to the door BEFORE mounting to the vehicle as pressing the hinge to the door required some firm pressure. I think if I mounted the hinge to the vehicle first...the pressure trying to put the door on would have broken the hinge all over again. I found this the easiest way at least on my S60 2002. Hope this helps anyone trying to do this themselves.

Well after reading all reviews, I was ready for trouble. Purchased 2. Two pins survived initial taps. It is not that people are breaking the pins. The pins are held in place by 4 little plastic weld points so to speak. Unfortunately the pin is not really in the whole to start with, so if you drive it one bit off center the pin breaks from its holding points which it is designed to do. I however, took the one that I didn't start right and took it to the work bench and got it in the whole.

I recommend taking the assembly to the work bench and tap them to pre-start them. You will hear the plastic weld points snap off and the pin will start to go in the whole. If the pin breaks off, you will need patience and a needle nose pliers to work it in! Then bring it to the car! Lightly tap them with a punch. At the end, I had to get a large screw driver that was larger than the whole and tap it with hammer in hand... pretty hard. The bracket will not secure unless you get get the pins flush with the bracket.

The problem is with the Volvo part that doesn't seem to have the pins recessed in the wholes for an easier start.

Took 20 minutes and hands of a surgeon to finesse the pins.

Well, only one of the pins survived. Punching the the pins was easy enough but trying
to hold the door and hinge while tapping in the first pin was the hard part. My box
didn't seem to have instructions but the pdf was just as good. I guess I'll buy some
screws for the last three.

Also, IPD's phone support was great! I called for an unrelated item and was really
helpful.

Didn't go well for me. I read the enclosed instructions and also read all the customer reviews. Then I called IPD customer service to ask if they had any sugestions to prevent the pins breaking off. They said don't be "willy nilly". Well five minuits later two I had broken off two of the four pins. It looks like this is nearly impossible to do without the tool the dealership uses. IPD should include a disposible plastic version of this tool. I would have paid more if I could have gotten such a tool.

Didn't go well for me. I read the enclosed instructions and also read all the customer reviews. Then I called IPD customer serveice to ask if they had any sugestions to prevent the pins breaking off. They said don't be "willy nilly". Well five minuits later two I had broken off two of the four pins. It looks like this is nearly imposible to do without the tool the dealership uses. IPD should include a disposible plastic version of this tool. I would have paid more if I could have gotten such a tool.

Follow the instructions, work awesome and was very quick to install. I used a small punch to knock the pins in, you really have to hit them to drive them all the way in, but i didn't have any issues.

Easiest fix ever, whole job only took about 20 minutes. I followed the advice of others
here and after one clumsy attempt to drive the plastic pin I just removed them entirely
and replaced them with #6 x 1/2" stainless metal screws. Next time the gas jockey
gets a little ham fisted with my fuel door I won't freak out.

This is a repair that pretty much anybody can do with some simple tools - don't shell
out big bucks to your dealer to fix your hinge.