Remove Broken Locking Gas Cap

I had the same thing happen to my '05. I got the dealership to replace the part with a regular gas cap sans locking mechanism.

--We managed to get the broken cap off, totally broke it.

Its a very scary business think! Spark and then Boom both will work. that was my option on the very begining but I bailed out-when it comes to fuel vapor I run and hide forget about the $$$$$$$$.

Good Luck

Easy to remove the old locking cap. Long wide tongue and grove pliers will remove the old locking cap with out risk of fire or damage.

Jeep OEM locking caps suck.... I have had two go bad... both in less than a year.

Well the factory locking gas cap finally refused to open for the second time just like has been reported by many. I called the dealer and did the Google thing, and the best answer to getting it off was break it off with a "honkin" pair of channel locks. When I try something like that I usually have collateral damage. After a little patient tinkering I was able to get it off and find the real easy way to remove it...with or without a key. Drill an 1/8" hole 1/2" from the edge and insert an ice pick or 3/32" drill bit (shank end) into the slots in the white ring and twist off. Doesn't ruin the seal on the cap so it can still be temporarily used until a new one is bought. Hope this helps others.

After about two minutes to locate my drill, I tried Clouseau's technique and the cap came right off in about 10 seconds!
Upon further inspection from the back side, the half inch suggested distance is important. The drill should come through the slots in the white nylon ratchet just outside of the rubber seal. There does not appear to be any metal or chance of vapors in this section of the cap, so it should be safe. You only need to drill through the black outer layer; as soon feel the drill go in, the job is complete.
Thanks again to Clouseau on this great tip.

Thanks guys, the drilling of the gas cap worked pain free.

Clouseau's answer did the trick,, once the 1/8" hole is drilled,, I inserted a finishing nail. wah lah.. opened up just fine,, way better than a key.. nobody will figure this out.. hahahhaa.. Thanks to Clouseau.. My issue was on a 2006 Wrangler LJ..

Great feedback. Please feel free to help out whenever you are on the site :)

Cheers, Ken