Gas tank door problem resolved.

[Beertinted]

Just a quick how-to on fixing a stubborn gas tank door that won't open. It's a pretty 'well, duh!' post, but figured it wouldn't hurt for reference.

This morning, I attempted to fill up but when I pulled the gas door latch release, nothing happened. So I pulled again. And again. Then harder. Then a line started forming behind me. Then I pulled harder and the cable popped out of the release lever. So I left with a quarter tank in my new-to-me 2006 V6 SR5.

I promptly searched this forum when I got to work and found a few tidbits here and there as to what might be happening. But since I've only filled this thing up twice since I got it, I really had no idea what to look for.

It was pretty simple to get the cable situated back the way it should be. There's a white retention block behind the latch that holds the fat part of the cable after you slide the thin (inner) cable in the slot. Then the thin, inner, cable has a round peg that gets locked into the actual latch lever. The reason I think mine was able to pop out, I think, was due to the previous person not locking the fat (outside) cable into the retention block. They just slid it in the groove.

Once all that is back in place, pull the lever and hold it (or rig something to keep it held) and use your fingers or a credit card to open the gas door from the right (rear) side.

Once you have the gas door open, bend the 'spring' (bent strip of flat metal) near the gas door hinge open a bunch. Release the latch inside the car and close the gas door. It should spring open now!

So here are a couple of pics in case someone else runs into this.

Showing the cable/latch pull under the steering wheel, then the metal 'spring' that needs to be bent out to make the door open in the future.

 

[guarddog]

Thanks!

I know you posted this awhile ago, but thanks! Bought a used 4Runner V6 (similar to yours, so that was good in that the fix should be the same). I think the previous owners were having problems with the door because it was bent in and the edge was scraping the body of the car when you opened it.

This was bothering me so when the fuel door was last open I bent it back into the place where it should be and not scraping. Well, I went to open the door for some reason and it didn't open!


Anyway, did a quick search and found your fix. i took some duct tape and taped the pull handle in the car open, then used a credit card like you said and the door easily opened. I then pulled and bent the tab outward, and voila! Fixed.

Thanks for posting, I know it may have seemed like a small thing, but was a huge help!

 

[bustedpop]

Thanks

Many thanks. My wife's '04 had the same issue on Friday and, thanks to your post & photos, I fixed it today…easy-peasy. 175K miles, all her's, and still strong as ever. Thank you again!

 

[dyintorace]

Thanks for the tip!

We recently bought a 2006 4Runner and started suffering the same issue. I found your post and realized that we are missing the fuel door spring altogether! Thanks for adding your original post!

 

[jrm]

But what if the cable CANT be reattached?

I would think that these being Toyotas and all that there would be some redundant set up for a lever like behind the rear driver interior quarter panel or a reachable lever from under the vehicle below the gas door.

If that's NOT the case, i'd have to say that's not very Toyota of them...yeah yeah a f-ing :llama:

 

[armabill]

It's OK to keep bending the spring tab for tension pressure. But eventually, as had happened to me, it broke.

You can replace the spring tab but the same thing will happen in the future.
Instead, I put a coiled spring in there. Get a coiled spring that doesn't have much tension to it, just enough to open the gas door.

Too much of a coiled spring tension could put too much pressure on the door lock tab and may distort it.

 

[longobongo]

Just a quick how-to on fixing a stubborn gas tank door that won't open. It's a pretty 'well, duh!' post, but figured it wouldn't hurt for reference.

This morning, I attempted to fill up but when I pulled the gas door latch release, nothing happened. So I pulled again. And again. Then harder. Then a line started forming behind me. Then I pulled harder and the cable popped out of the release lever. So I left with a quarter tank in my new-to-me 2006 V6 SR5.

I promptly searched this forum when I got to work and found a few tidbits here and there as to what might be happening. But since I've only filled this thing up twice since I got it, I really had no idea what to look for.

It was pretty simple to get the cable situated back the way it should be. There's a white retention block behind the latch that holds the fat part of the cable after you slide the thin (inner) cable in the slot. Then the thin, inner, cable has a round peg that gets locked into the actual latch lever. The reason I think mine was able to pop out, I think, was due to the previous person not locking the fat (outside) cable into the retention block. They just slid it in the groove.

Once all that is back in place, pull the lever and hold it (or rig something to keep it held) and use your fingers or a credit card to open the gas door from the right (rear) side.

Once you have the gas door open, bend the 'spring' (bent strip of flat metal) near the gas door hinge open a bunch. Release the latch inside the car and close the gas door. It should spring open now!

So here are a couple of pics in case someone else runs into this.

Showing the cable/latch pull under the steering wheel, then the metal 'spring' that needs to be bent out to make the door open in the future.

Do you know what the part number is for the spring? I bought a Toyota spring off eBay which stated it was for the 4th gen 4runner but it not fit.

 

[clh333]

Fuel filler door problem

Had a similar problem when I bought my 2007 4Runner Sport in 2011. Door would not open, had been bent and misaligned. No matter what other fixes you apply, also be sure to lube the hinge with penetrating oil. That alone fixed my problem.

 

[ragehell77]

thank you when i went to get gas last night this clip thing fell out of the gas tank door i could not figure out where it went until i saw your post. so thanks for saving this 3rd gen owner's time. now it's time to hit the trails. see you out there!!!!!