This has been a problem since day one. I pull into the gas station, pull on the fuel door release switch and I hear a pop and the door doesn't open. What a pain in the neck! After I put a new fuse in, it works okay. Anyone know what the problem might be? I've got a spare fuel door switch - are these solenoids prone to going bad? TIA!

 

That can be all sorts of wiring problems. It's obviously drawing too much current when you do that. It's time to start looking for shorts and bad connections. Fun stuff. Or you could just run new wires (I'm lazy).

 

That's always been my solution to everything. If it doesn't work just say **** it and run new wires.

 

What really sucks is when the solenoid gets jammed. I had to pry my door open with a screwdriver once.. It wasnt fun.

 

you don't have to pry it open. remove the interior panel to gain access to the solenoid and there is a little lever you can pull to maually open it.

 

The solenoid is essentially an electromagnetic hole that a spring loaded piston gets sucked into when the juice is turned on. It fits in there pretty snug, yet has to slide freely. If there got to be any rust on the piston, or scratches, ect (dirt/gunk?) then it's possible that it's just drawing too much juice, and not able to move the piston. Try simply spraying WD-40 on the door latch mechanism...It might even just be that and not the piston at all.

Anyway, before you start rewiring, I would look there.