Door Check Mount Broken

First things first, the truck is an 06 four door PreRunner. The story goes:
A couple of weeks ago the drivers door started to become difficult to close, not terribly bad but it wouldn't swing closed by itself. This was coupled with a 'popping' noise. Knowing what I know now, it was likely a crack, in the sheet metal of the door where the door check mounts, catching itself. Assuming the crack grew larger until one day I couldn't close the door at all. I was not at home so I had to force the door closed, heard the final pop and the result was the sheet metal where the door check mounts completely breaking off (seen in the pictures).

So my question is, has anyone experienced this? Or does anyone have any ideas for repairs?
I have a welder, access to most sheet metal tools and solid rivets, also can fabricate a patch; I'm just stuck on how to get access to the area. Any thoughts are greatly appreciated

 

It should be easy to access if you remove the door. The bolts are obvious. The wires should have a connector you can unclip right there at the hinge.

 

Should be able to weld it back on if you have to tools

 

Right on, thanks. I wasn't sure how far apart I could take the door and didn't want to start taking stuff apart if the efforts were going to be fruitless. We'll see how she goes.

 

I looked at removing the doors on my 2012 for wheeling. There's a connector that's easy to get to.

 

This happened to me today.. Did you fix it? How was the job?

 

It can be re-welded. If it has been over-stressed, check the limiter connection in the pillar, it's only a nut, spot welded inside the pillar. Can pop loose easily. If it does, the nut is gone, down inside the pillar.
A new washer type nut can be welded in, paint touched up, better than new.

 

Awesome thank you!!

 

This just happened to me . I just cant believe how thin the metal is and how fragil it is, being this something that its supposed to catch a door. I don't abuse my door at all.. I did forced it today when it got stuck open (I didn't have any 10mm and I was 30 miles from home). The catch it's stuck in the open position

 

Well, after doing a search I found that this is a common problem with the old siennas and also there are a few more threads about this on tacomas.
Ordered the part. I'll post a my solution next weekend (I'm confident that I have a solution, lol )

 

He @El Tano how did you get this fixed? My son's 07' Taco just had the same problem. The door check broke off. Any help on this would be great. TIA.

 

I did,and I'm very sorry I didn't do a tutorial but I was in a hurry. just happen to finish work at noon and wet home and did it.
I used a 4" flat steel square metal cover, link at the bottom. I used a grinder and a Dremel. took door panel out and cleaned all the twisted metal and tried to get it as flat as possible. Then I Basically created a plate with a square hole in the center and 2 holes for the bolts
put it on the stop and installed the stop inside the door in the position that it would normally go, used a thick washer on the other side and sandwiched the original door in between the plate and the washers.

https://www.homedepot.com/p/Steel-C...aUNEsOn14fUrXRtBJnhoCFqUQAvD_BwE&gclsrc=aw.ds

FYI: If you are comfortable removing the door, it will make the job soooomuch easier and cleaner. Specially if you know how to weld.

 

Great minds think alike! A few years ago the same thing happened to me. I did as above, and made my own template. I also got a new door check strap from Toyota dealer. After for five years, it’s still holding strong. I also painted it the color of the truck so it blends in. By the way, the Junction box cover was my wife’s idea!

 

Yeah I've got a new door check as well (Very expensive for what it is). Mine was all chewed up by the metal because it happened while I was working and the first time I had to close the door and then I had to open and close the door one more time.

 

1/4” fender washers work perfect! Sandwich the door with them and voila $6 fix and you don’t have to take the door skin off

 

My 2010 Tacoma TRD off Road just had this problem and I used Jonyfiver's solution and was able to fix it for $2.65 2 1/4 washers

 

I am not sure how you guys did this with the fender washers? Mind explaining further or posting a picture? I had this problem today, so frustrating.

 

If you notice the only way to remove the door check is from the inside, just loosen the nut and put a washer big enough to grab the metal without going through

 

Sorry I am being thick now. So the friction alone keeps it in place? This is my door. What I am unclear on is where the washers go. Behind the second lip, meaning the one on the inside? Or in between the two?