I have been down that road with new caps etc. Then spent an hour with various tools that were never designed to be placed down a fuel filler neck.

Let me see if I ever posted the solution and will put a link in. But this solved my problem well over a year ago.

http://www.peachparts.com/shopforum/showthread.php?t=174078

If your cap does not click that is clearly a problem.

Also look at the upper part of the flange inside the filler neck you will find that it is not at the same angle as the one on the bottom. The one on the bottom is wrong.

That will fix the problem. When I did this the various tools, ultra small "crowbar", talking 6" one, I clamped a pair of vise grips on them. Do not want to drop anything into the tank.

Please post the "successful" repair.

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raMBow

1999 E300DT Obsydian Black Metallic, Heated Full Leather Parchment options, E2, K2, 136,000+, best 36.5 mpg - GP's 12-04 & 11-12 Zero Stuck
2010 Honda Odyssey - The BrideMobile - best 26.5
(2) 2005 Honday Accord- (1 -Corporate 1 - Personal) - 110,000 4-cyl 30mpg
2000 VW Golf GLS TDI, Upsolute Chip (sold to Brother, now 300+k on it) 48.5 mpg like clock work
1987 Honda CRX HF - Sold 87,000 always over 50 mpg Max 67 mpg