Tacoma gas door replacement/fuel door repair due to rust

You could paint match your screw/bolt heads, or just paint them black.

 

Unfortunately I'm in this boat now, too. Has anybody successfully purchased the fuel door assembly and used their current painted skin by bending the tabs open, swapping panels?

 

Just buy this and drill out the rivets, then either bolt on for future replacement.... or re-rivet.

$45 Genuine Toyota 77305-04905 Fuel Filler Lid Sub-Assembly

https://www.amazon.com/dp/B00FWPGX0Y/?coliid=I3KDWUS0939GU5&colid=2OHGS56ZSHEP9&ref_=lv_ov_lig_dp_it

 

Mine rusted out last year. I've now got a primer black one. I didn't bother to paint it more than that. By the time this one rusts through, I expect to be over 300K on the truck and have moved on to something else.

 

This sparked curiosity. Wondering if anyone ever tried using a locking gas door parts from a car that came with it, and putting it on to work on their Tacoma. Then it might not be worth the effort since it has a finger notch which someone could stick a screwdriver in to force it open, now you have a damaged door and body body panel. A locking gas cap was my second purchase after getting mine, first being a good alarm.

 

Hi there, where did you find a locking gas cap? I’m told by my local auto parts stores that a locking gas cap is not available for a 2020 Tocoma with a V6 engine.

 

This fit my 2007.

$24 Stant Regular Locking Fuel Cap, Black

https://www.amazon.com/gp/product/B000C7YQ24?ie=UTF8

 

Absolutely. Bend the 4 tabs and the skin comes right off.

 

Slashaar and others are right. Bite the bullet and do it right. Tacomas, at least 2nd Gens, are notorious for this problem. I just replaced mine on my '12 - thanks to the excellent guidance here - and had the same problem on my old '10. The issue, as I heard consistently from several body guys and dealers, with just prying the tabs and swapping the old door on a new hinge is that the metal tabs aren't rugged enough to handle being bent and re-bent. They'll snap off or, if not, won't hold the door on the new hinge securely.

Go new, wet-sand, prime, wet-sand, paint or have it painted properly, and oil it. My door was $38 online. I'm sure you have a parts store that will mix a spray can of whatever you need for about $22. I used a local O'Reillys and asked for two-stage paint (separate cans of paint and clear) to allow for wet sanding (to at least 1000 grit) and blending into the quarter panel. You can get away with a single-stage paint if you only need to paint the door and touch up inside.

BTW, learned the hard way that there were several variants of White (040) in 2012. Learned I had the blue variant. That added a day....

 

My local dealer has the door assembly for $15 last I checked. EDIT: I was wrong, $31.

 

That's more like it! I don't think I could get a cabin light bulb from my dealer for $15, let alone a well-made gas door with a hinge.

 

I was probably thinking of the gas cap to be honest. Too many parts floating in my mind brain.

 

For information: I had a scraping sound when opening the fuel door on my '13. I thought it was dry hinges but 3 in one oil at the pivots did not resolve it. It turns out that the edge of the door on the hinge side was scraping the body when opened. A little bending adjustment with a flat screwdriver fixed the interference. Unresolved, this will lead to rust as there is bare metal now.

 

Woohoo, looks like I'm gonna get to join the club. Glad I'm not alone, but what a PIA.

 

Just posted a brand new in box OEM fuel door for sale in the 2nd Gen Marketplace if anyone needs one. Part number is 77305-04904.

 

Easy fix on painting fuel door.
I went with VINYL WRAP. It's a lot cheaper than paint and it's easy. My color is the metalic grey 1g3. the wrap is a great match. Bought the vinyl online from metrorestyling.com . You don't have to buy it by the roll. They sell in small sheets to accommodate your needs. I bought a 12''x12'' sheet for 4 bucks (ship 6.00). and have enough left to do the door handle wells that the cats have scratched up jumping up on the truck. I also bought a cheap vinyl squeegee kit (8.00) on Amazon and only out 15 bucks total on color. Total job under 75 bucks (with door). watch the vids on youtube on how to use vinyl wrap, very forgiving material, you can't go wrong if you are a DIY'er.
Hope this helps.
Later Lee

 

tagging for future use

 

keep some grease on the moving parts an should not be a issue again. thats what i've been doing with mine after is has been replaced not rust so far been over a year.

 

Every oil change I put a very small amount of Kroil on the hinges. My rust has gotten no worse and the door works smoothly. I have a paper towel to mop up any over dose.

 

Lol! I wish I would have known about this issue BEFORE my fuel door hinge rusted.