Broken fuel door hinge

[4rs]

My door does the rub and is misaligned too. I fear of twisting it back, that the hinges will snap. How does it even get jacked like this?

 

[L8Shift]

My door does the rub and is misaligned too. I fear of twisting it back, that the hinges will snap. How does it even get jacked like this?

This may help.. :spy:
http://www.toyota-4runner.org/4th-gen-t4rs/62825-how-remove-gas-door.html

 

[LIRunner03]

Mine just broke off while I was attempting to get gas last week. I purchased a new fuel door with rivets for $57 shipped and took it to my body shop who matched the paint perfectly and installed it for $90 cash. $147.00 total which is a waste, but the new door opens so smooth and it lines up perfect.

 

[Justinraf]

The pin on my hinge has also broken. Looks to have given way to rust. It locks fine but protrudes a bit in the locked position. I'm going to have a close look over the weekend to see if I can find a substitute for the pin. I'll let you know if I find a solution.

Did a solution ever come about? My ‘05 fuel door pin is broken and I don’t know how many more times it will open before taking it off will need to be the only solution.

 

[Terminator03]

My door does the rub and is misaligned too. I fear of twisting it back, that the hinges will snap. How does it even get jacked like this?

Trust me, it WILL break if you do try to realign it. I was very careful in applying pressure to straighten mine, and it literally took nothing to snap it. I’m still using it as one side of the hinge is still attached, but getting gas is a pain because I have to be super careful opening and closing it so it doesn’t gouge the paint at the bottom corner, and it doesn’t seem to open as far as it should anymore either, but I’m obviously not going to force it to open more than it wants to until I get around to replacing it. Fortunately, my truck is black, so matching the paint is way easier than a color that fades, or a metallic, but I still would rather not deal with it at all. What a crappy design!

 

[blueraven]

Here is the condition of mine. Thankfully no body rubbing going on. As fun as that sounds….:eyebrows:

OMG THIS HAS HAPPENED TO MINE! THANK YOU! Wonder how the guy with the "coat hanger hinge" worked out?

 

[blueraven]

My hinge is broken too. I just bought mine at the end of January. Who thinks to check the fuel door? I always will in the future. My door will not release unless the door pull is pulled out and held in position while also pulling door open with fingernail. For a few fill ups I always had someone with me to hold the fuel door pull. I finally realized that I could prop the pull in the open position by wedging my 4 D cell Maglite under it. Hope this helps someone. The broken hinge rod seems to be about the same gauge as coat hanger wire. Maybe I'll try using that.

Hey did the "coat hanger" work?

 

[TechWrench]

OMG THIS HAS HAPPENED TO MINE! THANK YOU! Wonder how the guy with the "coat hanger hinge" worked out?

That looks like a typical fuel door hinge failure. I tried the wire fix for the hinge, and it didn't work out well. Finally bought a new door assy., had it painted to match vehicle, and installed it. No further problems.

 

[Seasparrow]

Mine doesn't sit flat, it has always protruded out a little. I tried to make a couple of uneducated adjustments (pushed the heck out of it) but it didn't help.