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Has anyone actually fixed the misaligned fuel door?

Discussion in '4th Gen 4Runners (2003-2009)' started by Stuck CAPS, Apr 26, 2017.

  1. Apr 26, 2017 at 3:50 PM
    #1
    Stuck CAPS

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    Stuck CAPS [OP] Truck killer

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    My fuel door is misaligned. It'll pop open with the lever just fine, but opening it up, even when pulling on it to avoid scraping, I'll scrape it against the body. Is my only real option getting a new fuel door? Or has someone actually figured this out, so I can stop it from scraping, so I can just touch it up?
     
    Stuck CAPS, Apr 26, 2017
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  2. Apr 27, 2017 at 4:47 AM
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    RonT4R

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    RonT4R New Member

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    Lol, how do we have the same issues. Still looking into what I can do to stop it. Wish the fuel door was attached with screws like my old Tacoma instead of rivets so I could remove it and modify it.
     
    RonT4R, Apr 27, 2017
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  3. Apr 27, 2017 at 5:07 AM
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    bahndrvr

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    bahndrvr New Member

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    Didn't realize this was a wide-spread issue, would be as easy as drilling out rivets, replacing with screws for the adjustability, didn't have this issue on my 04 v6, but definitely have it on my 03 v8:) Once I get to a point where I have tinker time I'll fix it and put the fix up here, but that's not going to be really soon/quick.
     
    bahndrvr, Apr 27, 2017
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  4. Apr 27, 2017 at 7:27 AM
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    Stuck CAPS

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    Stuck CAPS [OP] Truck killer

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    FJ guys have this problem too :(
     
    Stuck CAPS, Apr 27, 2017
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  5. Apr 27, 2017 at 7:29 AM
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    Teamroper

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    Yep. Have an '06 with the same problem.
     
    Teamroper, Apr 27, 2017
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  6. Apr 27, 2017 at 4:59 PM
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    mr5vtps

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    mr5vtps New Member

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    My 08 Urban Runner has same problem.
     
    mr5vtps, Apr 27, 2017
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  7. Apr 27, 2017 at 5:00 PM
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    wnelax04sr5

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    wnelax04sr5 New Member

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    ive just been scratching my paint for 6 years, i think im numb to it
     
    wnelax04sr5, Apr 27, 2017
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  8. Apr 27, 2017 at 8:07 PM
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    Stuck CAPS

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    Stuck CAPS [OP] Truck killer

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    both my runners have and I'm wanting to stop it now
     
    Stuck CAPS, Apr 27, 2017
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  9. Apr 28, 2017 at 5:56 AM
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    keakar

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    keakar New Member

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    same thing for mine too, thinking the same thing, drill out rivets, add washer behind it for that clearance not to scrape and then screw or rivet it back on.

    how can you get access to the back side of it? just in case I want to use screws with nuts behind it

    well hell then, shouldn't there be a recall to fix it? scratching paint finish has to be a problem with rust at some point?
     
    keakar, Apr 28, 2017
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  10. Apr 28, 2017 at 7:55 AM
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    RonT4R

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    I'll look more into it this weekend since it seems to be a common problem. My 04 did not have this issue.:notsure:
     
    RonT4R, Apr 28, 2017
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  11. Apr 28, 2017 at 9:21 AM
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    alittleoff

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    On my former '14 Taco, I just put a plastic putty knife in the gap at the hinge, and bent the door away from the hinge.

    Steve
     
    alittleoff, Apr 28, 2017
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  12. May 5, 2017 at 2:03 PM
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    grave

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    grave New Member

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    mine creaks really bad when opening it, is that the issue at hand?

    i just thought the previous owner bent something and i just deal with it. didn't know it was a common issue.
     
    grave, May 5, 2017
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    Stuck CAPS[OP] likes this.
  13. May 17, 2017 at 7:58 PM
    #13
    Stuck CAPS

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    Stuck CAPS [OP] Truck killer

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    that's the sound, if you see can see between the door and the body, it'll prob be really scraped up
     
    Stuck CAPS, May 17, 2017
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  14. May 23, 2017 at 4:02 AM
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    RonT4R

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    RonT4R New Member

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    Fixed mine this past weekend, not for the faint of heart people, I ended up taking a plastic rod about 3/8" in diameter rounding the tip and I placed it on the area wear the fuel door was rubbing and I tapped it a few firm times with a hammer.
     
    RonT4R, May 23, 2017
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    Stuck CAPS[OP] likes this.
  15. May 24, 2017 at 8:14 PM
    #15
    Stuck CAPS

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    Stuck CAPS [OP] Truck killer

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    just to space out the body line and the fuel door?
     
    Stuck CAPS, May 24, 2017
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  16. May 25, 2017 at 4:37 AM
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    RonT4R

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    RonT4R New Member

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    Yes
     
    RonT4R, May 25, 2017
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  17. May 27, 2017 at 5:45 PM
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    wnelax04sr5

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    wnelax04sr5 New Member

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    filled up at a full service gas station today and the attendant cringed opening the door. after 6 years i might try to fix it
     
    wnelax04sr5, May 27, 2017
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  18. Jun 9, 2017 at 11:20 AM
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    poncho65

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    poncho65 New Member

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    New factory fuel doors are about 60 bucks from some of the online parts sources. It's very easy to simply drill out the 2 rivits on the old door. Attach the new door with 2 pan head phillips stainless screws with a serrated nut, or nut with lock washer. Gently pull back the rubber material around the fill neck for access. The fix is cheap and easy to do.....no more creaky, mis-aligned door rubbing on your paint!
     
    poncho65, Jun 9, 2017
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  19. Jun 12, 2017 at 9:05 PM
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    Stuck CAPS

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    Stuck CAPS [OP] Truck killer

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    Is this painted or not?
     
    Stuck CAPS, Jun 12, 2017
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  20. Jun 15, 2017 at 11:39 AM
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    poncho65

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    poncho65 New Member

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    fuel door 004.jpg fuel door 003.jpg
    The fuel doors come through in primer. You can have them painted to match....I installed mine "as is". Being that it's now attached with screws, I could take it off anytime and have it painted.
     
    poncho65, Jun 15, 2017
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  21. Jun 20, 2017 at 7:29 AM
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    bahndrvr

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    bahndrvr New Member

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    I messed with mine while at a gas station the other day, completely fucked it up lol. IT rubs worse now and having issues with the release working now, DOH. I'll actually have to remove it and fix it, probably just remove, reattach with screws and paint with a paint pen and clear it.
     
    bahndrvr, Jun 20, 2017
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  22. Jun 20, 2017 at 12:34 PM
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    Stuck CAPS

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    Stuck CAPS [OP] Truck killer

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    That's the boat i was in, I just put a towel over it and punched it reasonably soft a few times tbh. It only rubs beyond open 90* now.
     
    Stuck CAPS, Jun 20, 2017
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  23. Jun 30, 2017 at 9:03 AM
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    MP21

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    Yes, bought a new one. Total cost for rivets and door was less than $80 and I just bought spray paint in my color code online. Then cleared it and was done.
     
    MP21, Jun 30, 2017
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  24. Jul 26, 2017 at 1:55 PM
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    grave

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    forgot about this thread... a few months ago i smeared some lithium grease along the hinge and between the door and where it scrapes and... no more squeak! i'll probably have to reapply occasionally but that's fine with me.

    specifically:

    [​IMG]
     
    grave, Jul 26, 2017
    #24
  25. Oct 1, 2017 at 3:12 PM
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    Ric

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    Glad Im not the only one, with this issue.
     
    Ric, Oct 1, 2017
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  26. Dec 5, 2018 at 1:20 PM
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    djremix

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    djremix New Member

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    Sorry to revive an old thread. I have the same issue with my 04 4Runner. I bought a new door, painted it but I want to know from the guys that replaced the door, what did you do about the little spring that pops it open, there is none on my new door and I can't quite figure out how to get the old spring out and on to the new one...
     
    djremix, Dec 5, 2018
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