Replacing Gas Cap, Engine Cvr., Trunk Release Surround | FerrariChat
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Replacing Gas Cap, Engine Cvr., Trunk Release Surround

Discussion in '206/246' started by Crawler, Jul 12, 2006.

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  1. Crawler

    Crawler F1 Veteran

    Jul 2, 2006
    5,018
    #1 Crawler, Jul 12, 2006
    Last edited by a moderator: Sep 7, 2017
    The plastic surround for the three release levers on my GTS completely disintegrated. I got a repro part made from aluminum as a replacement. This seemed to make sense because the levers and mechanism still work perfectly.

    What I did not know is that reassembly is the mother of all frustrations. Because the parts are held in close proximity to the bulkhead by the cables, threading the shaft through the holes in the aluminum part and the three levers seems almost impossible. I have tried and tried and can't get it to go in more than about a half inch before it won't go any further. And forget about the return springs. I'll never be able to get them in the proper places working "blind", and even if I could, they would fall out before I got the shaft through (if I were able to do so).

    I have even machined a couple of thousands of an inch off the shaft. It goes freely enough through the plate and levers individually, but I'm damned if I can get it to work when everything's assembled.

    Can anyone help? Note that this is a RHD car, so the panel's on the opposite side from most. Will not having the return springs installed create a problem?
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  2. 246gts

    246gts Karting

    Jan 10, 2005
    134
    cheshire, uk
    #2 246gts, Jul 13, 2006
    seem to remember when I did same thing on my car I had to release the cables from the engine cover and the trunk catch at the other end to where you are trying to fit the levers etc. This then gave me enough space to twist the lever section around and fit the pin. You then have to refit the cables onto the catch for the engine cover and the trunk.

    Dave
     
  3. DinoDriver

    DinoDriver Formula Junior

    Mar 14, 2005
    537
    Leesburg, VA
    Full Name:
    Bill Ebert
    #3 DinoDriver, Jun 29, 2012
    Oh Boy! It's been almost 6 years to the day since the last post on this subject. Now I've got the same problem on #08118. dinodan, did you resolve your problem with your "self-destructed" plastic cover. Did the aluminum version work okay and was Dave's (246gts) advice the key to getting it all back in place? I've got to think that this problem is now common given the age of our vehicles. Any help/advice would be much appreciated.

    Bill
     
  4. Nuvolari

    Nuvolari F1 Veteran
    Owner Silver Subscribed

    Sep 3, 2002
    6,641
    Toronto / SoCal
    Full Name:
    Rob C.
    #4 Nuvolari, Jun 29, 2012
    These plastic assemblies have been breaking for a long time now and the aluminum replacement is a good option for those who want a reliable solution at the sacrifice of some originality as the alum part looks good but not perfect compared to the original part.

    As for the installation it is best to build your lever assembly off of the the car and then try and fit it in place. This is really one of those times where a ton of work is saved by fitting all new release cables. They are cheap and you will be working with all new parts rather than old junk. Behind the assembly there should be 3 metal tubes that feed the release cables to the trunk, engine compartment, and fuel filler door. Build the lever assembly with all new wires fitted and feed the wires through the metal tubes and make new connections at the related latches. It may seem like more disassembly but in the end you will do less work because you will never struggle with not having any space to put fingers and tools.
     
  5. DinoDriver

    DinoDriver Formula Junior

    Mar 14, 2005
    537
    Leesburg, VA
    Full Name:
    Bill Ebert
    #5 DinoDriver, Jun 29, 2012
    Thanks, that's good news. Would you happen to know where the aluminum replacements can be found? Does the locking bar properly mate with it?
    Bill
     
  6. TonyL

    TonyL F1 Rookie

    Sep 27, 2007
    4,203
    Norfolk - UK
    Full Name:
    Tony
    #6 TonyL, Jun 30, 2012
  7. GIOTTO

    GIOTTO F1 Rookie
    Consultant

    Dec 30, 2006
    3,916
    France
    #7 GIOTTO, Jun 30, 2012
    Last edited by a moderator: Sep 7, 2017
  8. DinoDriver

    DinoDriver Formula Junior

    Mar 14, 2005
    537
    Leesburg, VA
    Full Name:
    Bill Ebert
    #8 DinoDriver, Jun 30, 2012

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