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Hi Guys, I have read the other threads regarding the broken flap hinges.
This is a basic "How to Replace"

Drill out the 4 indents in the corners a 5mm drill is ample, don't go too deep just break thru the outer.
On the Left hand side there is a little panel, to remove this use a very small flat screwdriver and GENTLY prise the 2 small locators on the top (see pic)
Pull the plate out and top down to remove the locking mechanism, remove the wire connector.
Use a small probe, starting on the left hand side, push thru your drilled holes to push the tabs behind out of the way. These will break off if pushed hard.
Put your fingers in the hole where the lock was and pull out the left hand side. When it is just out, prise the rubber boot over the filler neck and wriggle the unit out whilst turning to the right hand side.

3542
3543
3544
3545
To fit the new unit, part number MB-A2536305902.
Insert the left hand (hinge) side first , pull the wire connector thru the hole and attach it to the lock mechanism. wiggle the rubber boot around the filler neck and push unit hard until fully in place, push the lock into the slot and push tabs back in place. Refit fuel cap holding wire in slot and refit filler cover plate. Simpelz.
MB want 2.5 hours and $600 Au. to remove and refit this part. Took me 25 minutes to get it out and 3 minutes to replace.
 

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Hi Guys, I have read the other threads regarding the broken flap hinges.
This is a basic "How to Replace"

Drill out the 4 indents in the corners a 5mm drill is ample, don't go too deep just break thru the outer.
On the Left hand side there is a little panel, to remove this use a very small flat screwdriver and GENTLY prise the 2 small locators on the top (see pic)
Pull the plate out and top down to remove the locking mechanism, remove the wire connector.
Use a small probe, starting on the left hand side, push thru your drilled holes to push the tabs behind out of the way. These will break off if pushed hard.
Put your fingers in the hole where the lock was and pull out the left hand side. When it is just out, prise the rubber boot over the filler neck and wriggle the unit out whilst turning to the right hand side.

View attachment 3542 View attachment 3543 View attachment 3544 View attachment 3545
To fit the new unit, part number MB-A2536305902.
Insert the left hand (hinge) side first , pull the wire connector thru the hole and attach it to the lock mechanism. wiggle the rubber boot around the filler neck and push unit hard until fully in place, push the lock into the slot and push tabs back in place. Refit fuel cap holding wire in slot and refit filler cover plate. Simpelz.
MB want 2.5 hours and $600 Au. to remove and refit this part. Took me 25 minutes to get it out and 3 minutes to replace.

Great info... I just replaced mine. I ended up drilling out the indents to remove the old pocket, as suggested. I saw an article that proposed removing it without drilling out the indents, but struggled.

The part was $150 from the local Mercedes dealership without the stickers; I'll replace those later. The three (3) stickers must be purchased separately and range in price from $10-$18+... I was told by the dealership the fuel sticker required proof of ownership. That's not really a big deal.. but I'm checking out less expensive options. I feel the decals/stickers are only important in resale.
 

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Just registered to say thanks @SteveG for the great info on DIY fuel door repair. I called the dealership first and found that they wanted $695 US to replace it!

I did not buy a replacement part but removed the broken part to attempt a bonded plastic repair. I first joined up the parts with good ol' superglue held tightly by a small screw drilled through both parts. Then I applied a liberal coating of PlastiFix over the seam, filling in the voids.

This PlastiFix polymer stuff is very strong and bonds to plastic better than any epoxy I've used. I think it's going to hold up just fine. If not, well I know how to replace it in under 30 minutes with a new part if it breaks again.
 

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Hi Guys, I have read the other threads regarding the broken flap hinges.
This is a basic "How to Replace"

Drill out the 4 indents in the corners a 5mm drill is ample, don't go too deep just break thru the outer.
On the Left hand side there is a little panel, to remove this use a very small flat screwdriver and GENTLY prise the 2 small locators on the top (see pic)
Pull the plate out and top down to remove the locking mechanism, remove the wire connector.
Use a small probe, starting on the left hand side, push thru your drilled holes to push the tabs behind out of the way. These will break off if pushed hard.
Put your fingers in the hole where the lock was and pull out the left hand side. When it is just out, prise the rubber boot over the filler neck and wriggle the unit out whilst turning to the right hand side.

View attachment 3542 View attachment 3543 View attachment 3544 View attachment 3545
To fit the new unit, part number MB-A2536305902.
Insert the left hand (hinge) side first , pull the wire connector thru the hole and attach it to the lock mechanism. wiggle the rubber boot around the filler neck and push unit hard until fully in place, push the lock into the slot and push tabs back in place. Refit fuel cap holding wire in slot and refit filler cover plate. Simpelz.
MB want 2.5 hours and $600 Au. to remove and refit this part. Took me 25 minutes to get it out and 3 minutes to replace.
 

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Hi Guys, I have read the other threads regarding the broken flap hinges.
This is a basic "How to Replace"

Drill out the 4 indents in the corners a 5mm drill is ample, don't go too deep just break thru the outer.
On the Left hand side there is a little panel, to remove this use a very small flat screwdriver and GENTLY prise the 2 small locators on the top (see pic)
Pull the plate out and top down to remove the locking mechanism, remove the wire connector.
Use a small probe, starting on the left hand side, push thru your drilled holes to push the tabs behind out of the way. These will break off if pushed hard.
Put your fingers in the hole where the lock was and pull out the left hand side. When it is just out, prise the rubber boot over the filler neck and wriggle the unit out whilst turning to the right hand side.

View attachment 3542 View attachment 3543 View attachment 3544 View attachment 3545
To fit the new unit, part number MB-A2536305902.
Insert the left hand (hinge) side first , pull the wire connector thru the hole and attach it to the lock mechanism. wiggle the rubber boot around the filler neck and push unit hard until fully in place, push the lock into the slot and push tabs back in place. Refit fuel cap holding wire in slot and refit filler cover plate. Simpelz.
MB want 2.5 hours and $600 Au. to remove and refit this part. Took me 25 minutes to get it out and 3 minutes to replace.
Thank you. This is great information. Appreciate it.
 

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Hi guys, now it's my turn. Took exactly 6 years of ownership. Quick question, do your US GLCs have the gas tank filler on the left or right side? I'm asking because I live in Trinidad, my car is RHD but easy to access parts from the US. Wondering if I'll have any issues with RHD vs LHD. Great tutorial by the way.
 
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