Dorman 924-140 Fuel/Gas Tank Door Hinge Compatible with Select Volvo Models

Quality product, don't expect less from a trusted brand like Dorman, bought an off-brand variant from eBay & it broke upon installation. No issues with this 1, worked like a charm; exactly what I needed.

Worked well for my Volvo gas cap is back to acting normal

This design by Dorman may actually match the original design of the fuel door hinge by Volvo. So, maybe Dorman is not to blame for this issue as much as Volvo is. The intent is that the hinge is mounted using 4 plastic expanders that work similarly to a dry wall anchor. Molded to the outside of the hinge, opposite the expanders, are 4 approximately 1/8" pins. It appears the theory is that you simply use a 1/8" punch and tap the pins through till they are flush, causing the expanders to expand. In my case, only 1 of the 4 pins properly disconnected from their molded position and went through the other side to cause expansion. The other 3 pins broke on the outside, leaving no hole or only a partial hole. In addition, on my own fault, I dropped one of the pins that broke and could not find it. In order to salvage the situation, here is what I did. I attempted to find an alternate source for the pins, something about 1/8". My first thought was that a toothpick might be about the right diameter. I pushed a toothpick through one of the holes but it really didn't seem like the expander expanded, plus, long term, I would have been concerned that the toothpick would rot. I then found some stiff wire I had laying around that was not 1/8 (ie .125"), but it was .10". I experimented and found that it did successfully expand the expander. So, I cut 4 pieces of wire at about 1/2" each. I had to drill out a couple of the holes. Then, upon mounting, I used just a little RTV on the back side of the hinge in hopes of providing just a little more support. Finally, after pushing the pins in about 1/2 way, I coated the very ends with just a small amount of JB Weld since I was concerned the pins might be looser than a snug press fit since I felt the diameter of my homemade pins were slightly smaller. Then, I pushed the pins in the rest of the way till they were flush. Of course, with this homemade solution, everything needed time to set, so you need to be prepared to allow the car just to set for a few hours, preferably a day. Given how you have to remove the hinge as shown by https://www.youtube.com/watch?v=HQovVzO2_FA, I don't think my homemade modifications will keep the hinge from being removed if it breaks again, though I will likely have to pry more since I used RTV to bond the hinge as well.

Fairly easy to install. It will probably take an average handy person about 20 minutes or so to figure out the install process. There are on line videos to also help. Well worth the cost. It will save you a bundle to do it yourself rather than pay the dealer to do it.

This product is certainly an inexpensive replacement that does what it is intended for. I had 2 issues. The first hinge arrived broken out of the box. I was sent a replacement immediately which I appreciated. The second issue were the 4 thin black “poles” that you have to tap in. They would not budge and eventually each broke off. So I had to find some random short screws and used those. After that, all was fine.

Worked great

Bought one Aug 2024, it’s July 2025 and it broke. I did just order a new one (same Dorman) for the convenience, but be prepared for it to be a somewhat temp fix…

All 4 tiny plastic pegs that are driven into the piece to make the fasteners expand snapped where they meet the hinge mount with a tiny amount of pounding directly in-line with their axis. I was also very nervous while snapping the door spring into this piece because it feels so flimsy. I ended up finding some tiny screws the same size as the pin and using those. Poor quality.