Fuel Door Cable- End Removal - 90 SHO

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sperold

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My plunger does not move any more to release the fuel door. It is rusted solid in the "open" position.
Tried to get the cable-end off at the gas door. Put a 15 mm socket on it, but the nut is rusted to the threads, I spun it around a few times and noticed my trunk located pull handle was being drawn into the plastic end contraption with every turn of the rachet. The inner cable must have been rotating in the sheath and dragging this little wire into the holder.
Tried holding the end of the threaded piece where the plunger comes out, while turning the nut with an open end wrench, but that did not work either.
Does that trunk located end piece come apart? If it does, does it help remove the cable?
Is my only choice to destroy the cable to get this thing off. It is pretty hard to do anything meaningful in the gas door area (like heating or grinding or cutting) with the filler neck fuming away right there.
Anyone had any luck getting these things off?
 

sperold

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Well, the day finally came where I had to do something, and it was not pretty.
Since I could not hold the threads on the fasterner inside the gas door area well enough to get the nut off, I had to go the desperate route. It has been rusted solid since I bought the car.
Went inside the trunk, pulled back the side carpeting and got the vice grips on the plastic end piece that is located right at the car body. That device quickly became scrap as it literally exploded when I clamped the vice grips on it. With that thing gone the cable was now detached from the plastic unit, but things were not well yet.
Fiddled with the metal remains of the plastic thing that used to be at the body metal and found it would still not co-opertate. I had to get a drill inside the trunk well and drill the remains of the back of this steel piece. The remaining unit just fell out after that happened. I was worried about a spark in that area but I took precautions and luckily it took only seconds.
Not a happy ending for the pieces, but it had been determined the old one was only junk to begin with.
Still had a bad feeling that I was unable to get the old one working.

I suggest to everyone to oil up that little beauty, because replacing it is a bad experience.
 

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