🔧 Durango - Fuel Cap Replacement

Replacing the fuel cap on your Durango is a quick job: remove the old cap and install a new one that seals properly. A good seal prevents fuel vapor leaks and helps avoid an EVAP warning light (like a “Check Engine” related to emissions).

Difficulty Level: Beginner | Estimated Time: 0.1-0.3 hours

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⚠️ Safety & Precautions

• ⚠️ Work in fresh air; fuel vapors are flammable.
• ⚠️ No smoking, sparks, or open flames near the fuel door.
• ⚠️ Avoid topping off the tank; it can saturate the EVAP system.
• ⚠️ Battery disconnect is not required.

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🔧 Required Tools

You'll need the following tools for this repair:

• Nitrile gloves
• Shop towel
• Small flat-head screwdriver

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Fuel cap (sealed replacement) - Qty: 1

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📋 Before You Begin

• Park on level ground and shut the engine off.
• Wait 1-2 minutes after shutting off the engine to reduce fuel vapor pressure.
• Open the fuel door.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Remove the old fuel cap

• Use your hand to turn the cap counterclockwise until it comes off.
• Use a shop towel to wipe the filler neck sealing surface (the round lip where the cap seals).
• Tip: Dirt on the lip can cause leaks.

Step 2: Transfer the tether (if your new cap doesn’t include one)

• Look for the small plastic strap (tether) that keeps the cap attached to the vehicle.
• If the tether is clipped to the old cap, use a small flat-head screwdriver to gently pry the clip open.
• A “tether” is the strap that prevents losing the cap.
• Snap the tether onto the new cap in the same position.

Step 3: Install the new fuel cap

• Place the new cap onto the filler neck and turn it clockwise by hand.
• Keep turning until it clicks several times (typically 3 clicks). Clicking means it’s tight enough to seal.
• Use nitrile gloves if you want to avoid fuel smell on your hands.

Step 4: Close up and clear any lingering warning (if it was on)

• Close the fuel door.
• If you had a check-engine light from a loose cap, it may take a few drive cycles to turn off after the seal is fixed.
• Tip: Don’t keep re-tightening daily—just click-tight once.

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✅ After Repair

• Start your Durango and confirm there’s no fuel smell around the filler area.
• After your next drive, re-check that the cap is still click-tight.
• If the warning light was on: it may clear on its own; otherwise a basic OBD2 code reader can clear the code after the repair.

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💰 DIY vs Shop Cost

Shop Cost: $40-$120 (parts + labor)

DIY Cost: $15-$45 (parts only)

You Save: $25-$75 by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 0.2-0.5 hours.

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🎯 Ready to get started?

HowToo makes it easy: same-day/2-day shipping on every part, plus all the tools and specialty tools you need! Check out the parts and tools sections below to add everything to your cart.