Gas Cap Pops Open

Try a bit of wd40 on it and work it in and out. The switch can be removed easy enough

 

I know i had to change mine about 25 years ago when it totally failed. I cannot remember the setup. Put a scratch mark on the plunger and Get someone to press the button, see how far out it travels and does it go back to the same place. Can the flap be adjusted by shims at the hinges

 

The plastic catch which the solenoid button inserts into and the gas cap hinge can be adjusted to a bit more reach for the button to catch more fully.

 

It's extending correctly; that's the maximum:

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Is your black plastic latch correctly fixed or loose/too far forward?

 

Loosen the bolts on the plastci catch and pull it out a tad. Or you can also adjust the door hinge and get the door to rests a little bit further to the right.

 

fyi, on my car the catch pin measures 9mm in full extension.

 

Ha, that's like something I would do. That's why I know on my cab you get at it through the wheel well. Maybe this a right of passage for us Mondial owners! Clean the contacts on the wiring too.

I did sort my mysterious popping door by adjustment. You need a very small amount of extra reach by the plastic to both close the door easily and for it to hold closed. Too much and it won't close easily, you don't want to unduely wear or break the plastic piece.