Tacoma gas door replacement/fuel door repair due to rust

Does your Tacoma suffer from the annoying broken (or nearly broken) fuel door hinge?

Here’s a pictorial guide on how to replace your Tacoma gas door:
1. Regularly oil spray that hinge and you won’t have this issue
2. If you didn’t do the above, order new door from Toyota. Mine was between $35-$45 USD.
3. Paint to match (prime first). Get your paint code off the VIN sticker and any parts store can order a can for around $9.00 USD.
4. Drill out the rivets holding the old door on. Use various sizes to work up to a 7/32 (or close to it). Use patience with this as you don’t want to damage the metal behind the hinge. Once you drill the rivets, give the hinge a tug and pull it out. I used a small pry bar to pop them the entire way out.
4. Clean and paint the area behind the door if needed. Especially if any exposed metal from drilling the rivets. I filled the holes with grease to be safe.
5. Be sure to take latch off the old door first and install on the new door before putting on the truck. The screw holding the latch off is on tight, I used a small impact driver to loosen it.
6. To install the new door you can use new rivets, a bolt and nut (from behind, access through the little compartment that pops out from the bed), or rubber well nuts. I used the well nuts as they didn’t require me to reach from behind to hold a nut. Basically they expand once you thread a screw into them and it holds the hinge in place from the back side of the mounting surface. I did not want to use rivets in case I ever wanted to remove the door again easily.
7. Tweak if needed to get it lined up.
8. Spray the new hinges with WD40 or similar lubricant and do it several times a year (or get it re-oil sprayed)
9. Enjoy having both hinges on your fuel door!

Tags: tacoma fuel door replacement, toyota tacoma gas door hinge replacement,

 

This deserves a sticky.

 

I read your post completely because mine was getting to where it would not open completely. I shot a small amount of Kroil in the hinge movement, let it sit and worked it pretty good. Cleared the problem up rather quickly. I appreciate the tip on the oiling periodically.

 

No problem! I get my trucks oil sprayed twice a year but by the time I bought this one it was too late for the hinge, so yes, great practice to keep it lubricated/protected.

 

does the new fuel door from toyota come with the hinge? what size well nuts did you use?

 

nice fix.

 

Yes, the door and hinge are one assembly through Toyota. The well nuts I used are 3/16

 

Thanks so much for posting this. My fuel door came off the hinge frame a few months ago and I had been trying to figure out how to fix/replace it. I saw some other threads on here that weren't quite as useful. I ended up getting a new fuel door/hinge assembly for $35, but then I had to swap my fuel door onto the new hinge as its hard to find Pyrite Mica color and didn't want to pay a body shop to paint it. Also, I couldn't find the correct size well nuts at 2 different hardware stores so I ended up drilling out the rivet holes and sizing up (made me a bit nervous). Anyways, the door works like a charm now and I sprayed the hell out of with with Fluid Film.

 

What was the part number you used to order the door?

 

I have the same issue. Cleaned it up and keep it oiled but I will be looking to do this in the future. Thanks for the write up!

 

What size well nuts did you use? The holes are pretty small so I’m not sure if you drilled them out bigger?

 

I had to drill mine out a bit larger in diameter, but I used 8/32 well nuts. I also snapped the bolt holding the door spring to the door itself but I’ll have a new one Tuesday. Aside that little setback, all went smooth

 

Are those actually rivets or pressed in studs with backing nuts? On my Tundra is was studs.

 

Just did this fix on my 2011. Fuel door (part #

$45 77305-04905 Fuel Filler Lid Sub-Assembly

77305-04905), paint and stainless steel hardware was less than $90. Thanks OP for the directions.

 

Ugh, my fuel door has two or three paint chips and it’s been scraping the back of the compartment every time I open it since I bought the truck almost four years ago. I should really look into doing this repair and repainting the area behind the door that has been scratched. Good thing I’m made of money...

Anyone know if I can get BSP paint in a can?

 

Great thread. Ive been putting off figuring out what to do with mine since i bought it 6 mo ago. Bottom hinge is snapped

 

09TRD - Not sure what BSP paint is but here's what I ended up doing... I went to a local professional PPG automotive paint distributor and had them match my paint (FYI - your trucks 3 digit color code is on the driver side door jamb) and mix up a can of PPG Deltron aerosol. You'll also need to buy a can of clear coat. The base paint and clear set me back $58.

 

BSP = Black Sand Pearl (209)

 

This just happened to me last week. The hinge was junk from day one, and after 1 year it finally broke. I also noticed my door and the framework seemed to be loose. Almost like the little metal tabs should be bent to hold the door in place.

Excellent write up OP, and something I will have to perform real directly. If not the top will break and I won't have a fuel door.

 

Little pricey but I like this Idea. How did it turn out? Haha, just realized those were your pics above. Looks good!!!!!