[ortiz_kt]

Thank you for posting this information. Mine broke and I was able to replace it after removing the fuel cover. I used an allen wrench to help turn it into place. If it doesn’t latch when you close the fuel door, most likely it is upside down.

 

[CampinMike]

Thanks Phil and Luis! I just fixed our 2018 with the same part. It's crazy chrysler still doesn't show it as fitting the older vans after all this time.

 

[Robin S]

What is the female part that is spring loaded called? I am having trouble with my cap less fuel door that won’t close right. The plunger is perfect and it seems the spring loaded lock mechanism or housing is not guiding and locking the plunger.

 

[billiam529]

So I have been having this exact issue and fixed it so I wanted to share what I found out since it took me quite a bit of time to research to resolve. I have a 2017 Chrysler Pacifica Hybrid and the plunger piece fell off. I went on several website trying to find this part and every single customer service person told me to try buying either some $50 or $100 part. I ended up throwing the dice and trying out part# 68524040aa which is a plunger for a 2020-2022 Pacifica or Voyager. The customer service rep contacted me immediately and told me it did not fit my vehicle. I told them it was only a couple bucks plus shipping so send it anyways. It is a little tricky to install correctly but it worked. I actually installed it on the vehicle side first to figure out the correct orientation and then I took it off and installed it on the lid itself. I hope this information helps someone else out because I have way too much time and effort invested in this issue.

-Phil

Are you able to share how you installed this piece? I've had the same issue but cannot figure out the installation. Thanks.

 

[billiam529]

I recently bought the plunger part for my 18 Pacifica....took 2 minutes to repair,and works perfectly.

are you able to share how you installed?

 

[CampinMike]

are you able to share how you installed?

IIRC you just push and twist it off. and put the new one on the opposite... If you look at the replacement part it should be obvious. It's about as easy an auto repair as you can get (once you can find the part number and order it). It's stupid Chrysler says it isn't replaceable on the older ones... when it's the same part as 2022-23.

 

[billiam529]

IIRC you just push and twist it off. and put the new one on the opposite... If you look at the replacement part it should be obvious. It's about as easy an auto repair as you can get (once you can find the part number and order it). It's stupid Chrysler says it isn't replaceable on the older ones... when it's the same part as 2022-23.

I have the replacement part. The old one fell out apparently so no removal. Just wasn't sure about the reinstallation...I tried twisting into place but I may not have turned it far enough...did you use pliers or some other means to twist it in?

 

[tdimarzio]

Hi, I had the same problem on my Chrysler Pacifica 2019 model. The part is called Plunger and Mopar sells it at this location: 2020-2022 Mopar Plunger 68524040AA | My Mopar Parts
It is part 68524040aa.

In the Diagram it is part #5 and worth $3.89 today June 2, 2022.
View attachment 50141
View attachment 50142

Extremely helpful. Thank you.

 

[rickl102609]

I recently bought the plunger part for my 18 Pacifica....took 2 minutes to repair,and works perfectly.

Are you able to share how you installed it, I have the part in my hand, just got it today, just not sure how to install

 

[Big PHEV]

So I have been having this exact issue and fixed it so I wanted to share what I found out since it took me quite a bit of time to research to resolve. I have a 2017 Chrysler Pacifica Hybrid and the plunger piece fell off. I went on several website trying to find this part and every single customer service person told me to try buying either some $50 or $100 part. I ended up throwing the dice and trying out part# 68524040aa which is a plunger for a 2020-2022 Pacifica or Voyager. The customer service rep contacted me immediately and told me it did not fit my vehicle. I told them it was only a couple bucks plus shipping so send it anyways. It is a little tricky to install correctly but it worked. I actually installed it on the vehicle side first to figure out the correct orientation and then I took it off and installed it on the lid itself. I hope this information helps someone else out because I have way too much time and effort invested in this issue.

-Phil

THANK YOU! The stealership wanted $900 to replace the entire fuel door so Like you tried the 68524040aa part and it worked great! Check engine is off, door works well.
How to install: open the fuel door, on it you'll see a ~3/8" hole with 2 notches opposite of each other. THe plunger has ears that fit into those notches. Turning the plunger sort of wedges itself firmly into place. I used pliers with a cloth to force it without much scratching. Trick is to get the orientation right before install by pushing the plunger into the female (body) side of the latch, it wont work if it's not oriented correctly - sort of like a key going into a lock, it wont work upside down. Also make sure you dont damage or move the rubber cover out of it's slot on the plastic piece (you'll see it) as I'm pretty sure this is the spring that flips the door open.

 

[SnapMan]

Thank you all for this Thread!
The 68524040aa part didn't work for my 2021 Pacifica Hybrid Limited.
In my model, the fuel door locks and can only be opened from the car (Chrysler is claiming for some safety reasons).
When I went to the dealership they suggested to replace the entire thing (which was too expansive and would take too long).
You can see A pictures of my original plunger vs 68524040aa are attached.

Plunger_Pic_02_Side.jpg

• SnapMan
• Sep 14, 2025

Eventually, I have modeled the plunger and 3D printed it.
I can send the model if anyone want to print it.

 

[dbri306]

Thank you all for this Thread!
The 68524040aa part didn't work for my 2021 Pacifica Hybrid Limited.
In my model, the fuel door locks and can only be opened from the car (Chrysler is claiming for some safety reasons).
When I went to the dealership they suggested to replace the entire thing (which was too expansive and would take too long).
You can see A pictures of my original plunger vs 68524040aa are attached.

Plunger_Pic_02_Side.jpg

• SnapMan
• Sep 14, 2025

Eventually, I have modeled the plunger and 3D printed it.
I can send the model if anyone want to print it.

Please send me the program. Much appreciated.