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Dodge Ram 1994-Present: How to Replace Fuel Door

Do you want to replace your stock fuel door with a locking or custom billet door in your Dodge Ram? This article will show you how to get it done, step by step.

By Brett Foote - July 23, 2015

This article applies to the Dodge Ram (1994-Present).

Stock fuel doors are boring but functional. But what if you want a little extra security to keep misfits out of your gas tank? Or perhaps you just want to install a custom looking billet door? Both have their place in the world, and either is a good choice depending on your needs and wants. A locking door can be keyed to match your truck, which is a convenient way to protect your gas tank. An aftermarket billet door can also be bought with a lock, and gives your truck a custom, sporty look. Whichever you decide to install on your truck, the process is easy and doesn't require many tools. Keep reading and we'll show you how it's done.

Materials Needed

  • 1/4" drill bit and drill
  • Phillips screwdriver
  • Allen key

Step 1 – Remove stock fuel door

The stock fuel door is held in place by rivets. Open the fuel door and use a 1/4" bit and drill out the rivets. Use the Allen key to remove the corresponding bolts, then pull the fuel door out. Remove any rubber grommets or lining inside the well.

Figure 1. Drill out the rivets holding the stock fuel door in place.

Step 2 – Align new fuel door

Most aftermarket fuel doors come with an adapter so that they can fit various makes and models. Remove any screws or hardware from the adapter and install it in the spot where you removed the rubber grommets. Don't fully tighten it down just yet though. Set the new fuel door in place and ensure the lines and holes all line up correctly. If they do not, adjust the adapter until they line up, then tighten the screws.

Figure 2. Make sure all holes align before tightening up the screws.

Step 3 – Install fuel door

Install the latch assembly onto the fuel door. Set the fuel door in place and install the washers and bolts that come with the door to secure it into place. Tighten the bolts on the front of the fuel door.

Figure 3. Tighten the exterior bolts to complete the installation.

Featured Video: Installing a Billet Fuel Door

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