Odd Gas Cap

firefighteremt3100 · April 30, 2005

Ive got a 2004 Silverado LT that has a unique gas cap with a plastic tether that is too short to allow it to hook onto the fuel door while fueling. Unlike most gas caps that are the screw on type, the one on my truck has 2 notches on either side of the cap that allow the cap to be pushed straight in, then rotated not quite a quarter turn. Ive checked with my dealer and they are trying to find out from GM what the deal is. Computer keeps telling me the wrong part #. Anyone else have this gas cap and corrected the problem?? It really irks me when I go to fill up and I have to let the gas cap hang there and bang against my fender because *cough* someone was too cheap Ã©YÄut a long enough tether on.

GM-Tech · April 30, 2005

Check your owner's manual for proper use of that clip in the gas door. The tether is NOT what you hang over that little clip on the gas door. That clip is designed to set the lip of the cap in it. Yeah, crazy, I know, but that's the way it was designed.

You can buy new, correct gas caps until the cows come home and they'll all be the same. I think there's a TSB on this somewhere.

GM-Tech · April 30, 2005

Here ya go. Looks like they might have come out with a cap with a longer tether by now, since this is dated April of last year.

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Adm Msg - Fuel Cap Tether Strap Too Short #VSS20040091 - (Apr 13, 2004)

Fuel Cap Tether Strap Too Short

2004 Full Size Pickups and Utilities

Except Engine Option L59

There are two different types of fuel caps used on all 2004 full size pickups and utilities with gasoline engines. A treaded design is used with option L59, the E-85 5.3L engine. A ¼ turn design is used with all other gas engines. The ¼ turn design has a shorter tether strap and will not allow the fuel cap to be draped over the hook on the fuel filler door. However, the cap can be retained in the hook by the lip of the fuel cap. The two different design caps are not interchangeable, so ordering a replacement will not correct the short tether strap condition. The strap will be lengthened with the start of 2005 model year production and a replacement service part with a longer tether for the 2004 model will also be available at that time. You will be advised of the part number when the service part becomes available.

GM bulletins are intended for use by professional technicians, NOT a "do-it-yourselfer". They are written to inform these technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions, and know-how to do a job properly and safely. If a condition is described, DO NOT assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See your GM dealer for information on whether your vehicle may benefit from the information.

WE SUPPORT VOLUNTARY TECHNICIAN CERTIFICATION

mmmikkke · April 30, 2005

Adm Msg - Fuel Cap Tether Strap Too Short #VSS20040091 - (Apr 13, 2004)
Fuel Cap Tether Strap Too Short

2004 Full Size Pickups and Utilities

Except Engine Option L59

There are two different types of fuel caps used on all 2004 full size pickups and utilities with gasoline engines. A treaded design is used with option L59, the E-85 5.3L engine. A ¼ turn design is used with all other gas engines. The ¼ turn design has a shorter tether strap and will not allow the fuel cap to be draped over the hook on the fuel filler door. However, the cap can be retained in the hook by the lip of the fuel cap. The two different design caps are not interchangeable, so ordering a replacement will not correct the short tether strap condition. The strap will be lengthened with the start of 2005 model year production and a replacement service part with a longer tether for the 2004 model will also be available at that time. You will be advised of the part number when the service part becomes available.

<{POST_SNAPBACK}>

I took my 2005 2500HD in a few weeks ago because of this same defect. The service rep decided that they are *all* that way and there is no replacement.

Now what should I (or any other forum member similarly aggreved) do?

Take a copy of this service bulletin with me?

firefighteremt3100 · April 30, 2005

Just to give a little more info, my dealer here I tow for so Im pretty well considered an employee so I know these guys arent screwing around with me. The parts manager ran into this same problem about a year ago on another vehicle and he said if he recalled right, GM had released another "fix" for this problem but he didnt have the part number, so he is trying to get it through GMs techline I think he called it. I just wondered if anyone else had that problem. As far as setting the lip on the tab, I've tried that and it doesnt stay. As soon as the wind hits it or you gently bump it, it falls off, and SLAM against the truck. Really tends to irk you when you are trying so hard to keep the scratches and dents off for as long as you can. I'm glad Im not the only one having this problem though. If I find out anything before another post is made, I will gladly put it here for others to use as well. As always, thanks for the very helpful responses. Its greatly appreciated

GM-Tech · April 30, 2005

I took my 2005 2500HD in a few weeks ago because of this same defect. The service rep decided that they are *all* that way and there is no replacement.

Now what should I (or any other forum member similarly aggreved) do?

Take a copy of this service bulletin with me?

First of all, it's not a defect. It was [badly] designed that way, but according to what that admin message says, the longer tether was put into use at SOP for 2005, so you should have it. On the other hand, that info is a year old, so who knows what has transpired in that time.

Yes, you could take a copy of that information in with you. If your parts department can't come up with this revised cap, they have a parts technical assistance number they can call to find out the part number or to see a new design was ever released.

mmmikkke · April 30, 2005

I took my 2005 2500HD in a few weeks ago because of this same defect. The service rep decided that they are *all* that way and there is no replacement.

Now what should I (or any other forum member similarly aggreved) do?

Take a copy of this service bulletin with me?

First of all, it's not a defect. It was [badly] designed that way...

<{POST_SNAPBACK}>

Interesting that GM can just walk away from the problem like that; in my book of common sense, it's a design defect as opposed to a manufacturing defect. There are other notorious design defects you can probably recall through history; the side saddle gas tanks on the 73-87 pickups is an example. And it's likely, over the life of the truck, all those fill-ups will introduce a measurable amount of dirt into the fuel system. Think of how the cap edge will pick up a little grime every time the cap bumps up against whatever road grime has accumulated on the body panel. So my fuel filter is going to get dirty faster, and there will be microscopic particles, and probably even some undesirable chemicals that can't be filtered, which get past the fuel filter into the fuel injection system, so it's a serious design defect in my opinion.

There's a chance that I can solve the problem myself without negatively impacting the strength or corrosion resistance of the door. A 5/16 diameter bolt (roughly), coupled with an S-hook, might do the job. There's an appropriate sized hole on the back of the filler flap that would serve as the receptacle for the bolt. I'll probably have to saw off the bolt first (and grind it refine the sawed edge), to make it appropriately short, and then bend the S-hook around. But I checked the micro-strap that GM provided with this defective design, and it'll make it to the S-hook with maybe another 1/4" to spare, so it should work out about right. If I do this, I'll post a picture in this thread.

redvett · April 30, 2005

I have a 04 K1500 EXT shortbox 5.3L and the tether is attached to the door. I have no problem hooking the tether on the hook. The P/N 10346666

Hope this helps.

Mr. Smith · April 30, 2005

You are kidding right? You have more trash in the gas along than what minute particles you "might" introduce to the system because of the gascap tether?

My 97 doesn't have a tether on the cap and I have been picking up all this dirt from the back of the gascap door when I store it there during fill-ups and didn't realize it.

I thought I seen silly stuff before but this post wins the prize, geez.

I took my 2005 2500HD in a few weeks ago because of this same defect. The service rep decided that they are *all* that way and there is no replacement.

Now what should I (or any other forum member similarly aggreved) do?

Take a copy of this service bulletin with me?

First of all, it's not a defect. It was [badly] designed that way...

<{POST_SNAPBACK}>

Interesting that GM can just walk away from the problem like that; in my book of common sense, it's a design defect as opposed to a manufacturing defect. There are other notorious design defects you can probably recall through history; the side saddle gas tanks on the 73-87 pickups is an example. And it's likely, over the life of the truck, all those fill-ups will introduce a measurable amount of dirt into the fuel system. Think of how the cap edge will pick up a little grime every time the cap bumps up against whatever road grime has accumulated on the body panel. So my fuel filter is going to get dirty faster, and there will be microscopic particles, and probably even some undesirable chemicals that can't be filtered, which get past the fuel filter into the fuel injection system, so it's a serious design defect in my opinion.

<{POST_SNAPBACK}>

robot225 · April 30, 2005

Same problem on my '04 as well. I've checked with my dealer as well and they can't seem to find a part with a longer tether either, so if anyone has it, I would definitely like to know.

I've popped my tether out of the hole and just hang that in the hook on the door. It works fine, but i'd rather have it attached.

redvett · April 30, 2005

If your tether at least on 04's isnt hooked to the door then you cannot hook it on the hook.

mmmikkke · April 30, 2005

You are kidding right? You have more trash in the gas along than what minute particles you "might" introduce to the system because of the gascap tether?

My 97 doesn't have a tether on the cap and I have been picking up all this dirt from the back of the gascap door when I store it there during fill-ups and didn't realize it.

I thought I seen silly stuff before but this post wins the prize, geez.

So I guess you won't mind if silly me comes over and puts some dirt in your gas tank.

The fact remains that we have a design defect that causes measurable harm. Do you want to take over responsibility for this design defect? I'll send *you* the bill.

Greg · April 30, 2005

I thought it was just a problem with my SD. I don't have a problem placing the cap on the hook with the hook between the outer and inner wall of the cap. It seems to hold OK.

redvett · May 1, 2005

Where is the tether attached to the vehicle? If its attached to the body is in the wrong place. It should be attached to the door.

budone · May 1, 2005

I took my 2005 2500HD in a few weeks ago because of this same defect. The service rep decided that they are *all* that way and there is no replacement.

Now what should I (or any other forum member similarly aggreved) do?

Take a copy of this service bulletin with me?

First of all, it's not a defect. It was [badly] designed that way, but according to what that admin message says, the longer tether was put into use at SOP for 2005, so you should have it. On the other hand, that info is a year old, so who knows what has transpired in that time.

<{POST_SNAPBACK}>

Nope, not on 2005 truck....