Gas Cap Lock - Modifying

90porsche08 November 13, 1990
Subject: Modifying Gas Cap Lock
Model Group

924S,
2
944/S/S2/T

Part Identifier Number

2006 9009
ATTENTION: Service Manager/Service Technician

Models Affected: 924S, 944/S/S2/T

Concern: Gas cap locks can be modified from 7 tumbler locks to 4 tumbler locks. This modification will prevent this lock from being used to duplicate the door/ignition key.

Figure 1:

Service Information: This modification does not interfere with the one key system.

1. Disassembling gas cap (to transfer lock cylinder)

New style cap (Figure 1) Hold gas cap in a vise with soft jaws and light pressure.
Vehicle Information: The 4 tumbler gas cap lock (new version) is in production as of:

VIN 94 MN 41 0103 944 S2 Coupe VIN 94 MN 44 0101 944 S2 Cabriolet

Figure 2:

Use two flat blade screwdrivers to pry between the plastic cover and the metal ring (Figure 2).

Figure 3:

Service Information (cont.): Former version gas cap (Figure 1)
Cap cannot be held in vise. Carefully pry around the cap with a putty knife (Figure 3).
The plastic cover may be lightly heated in the area of the lock cylinder to make disassembly easier. Do not heat the rim.

When plastic cover is separated, remove lock assembly from cover.

2. Disassembling lock cylinder

Figure 4:

Pry retaining clip out of lock housing to release and remove cylinder (Figure 4).

Figure 5:

Service Information (cont.): With a small screwdriver or scribe, break off the retaining tangs,
(arrows, Figure 5) of tumblers # 4, # 5 and # 6 (counted from the
key entry end). Be careful not to damage the cylinder. Remove
and discard the tumblers and springs. Insert key and check
smooth operation of remaining tumblers.

Figure 6:

3. Reassembly

Put a light coat of door lock grease (Part Number 999 917 751 00) on the lock cylinder and install it in the lock housing. Press the cap assembly together by hand until an audible "click" is heard (Figure 6).

Figure 7:

Service Information (cont.): Check operation of the lock.

Finally, mark gas cap with a punch mark in the area of the Porsche trademark (Figure 7) and reinstall.