07 Access Cab - Broken Door Hinge : HELP!!

Just had the same problem with my 05 Tacoma Access Cab driver side door. Have never had wind blow the door open. No accidents. Just heard the odd click opening the door this past weekend. Called my service coordinator Monday. Went to Priority Toyota in Chesapeake, VA the next day to the same person I always see and same senior master mechanic who alway works on my vehicle (after having sent close up pictures the day prior). After 90 minutes they told me it could not be repaired (obviously not true) and that I would have to go to the body shop. Body shop estimator let it slip this had been a problem with the Sienna (my wife has one), so contrary to what I was told, not a heretofore unseen or rare issue for Toyota (like the clutch problem). Naturally, the estimator said it could not be repaired and the door would have to be replaced - for $2,119.98. Laughed at him and went back to the service department and asked for the service department manager and explained that he personally needed get on the phone to corporate and find a solution, all the while expecting that others had this same part fail and/or that Toyota was hiding a known problem. In looking for an illustrated parts list for the door, came across this thread (same site where I researched the known clutch problem that Priority Toyota did not want to admit to and used successfully against the company/dealership). Before contacting my machinery repairman friend to fix it with his assistance if necessary, I decided to call Checkered Flag Toyota in Va. Beach where I bought the vehicle in 05. Girl I spoke with just told me "yes, we can fix that . . . service cost would be $145. I'll have to check on parts price." Hope this helps someone.

 

How'd this hold up?

 

I know this is an old post.
I did have this happen to my drivers door on my 2000 Tundra. Not as bad, just cracked. Tundra Solutions makes a plate that can be welded on or bolted on depending on the extent of damage.

 

Thanks for this, I looked these up and they look good if you can slip them inside the door. Putting them on the outside doesn't really mitigate the big stress event (door opening).

Just for the record, here's a good weld fix video. I have nothing left really to attach to, so I'm going down this path and getting it professionally welded. Also I think having

 

Wow, this is a brutal problem that I've never seen until today. Also @bbinSF, great video, thanks for sharing!

 

I'm looking at a different door plunger which has female threads instead of the male studs. I can open those up and use longer bolts to sandwich tighter. Still, cannot understand how there is a rub between an unmolested window guide and the plunger. I'm suspecting the door catch is not an exact fit part.

 

It doesn't have to be expensive to fix. Mine broke a month ago. I just cut about 4-5" off a ratchet strap and used 2 self tapping screws. Total cost maybe 5 cents. It works fine and this isn't unusual with older trucks. Jeeps have used the same concept forever.

I wasn't able to get the old piece out so I just pushed it into the door.

 

I just bought a similar door hinge for a Corolla. It has female threads on it.

$13 labwork Drive Side Front Door Check Stop Replacement for Toyota Camry 2012-2015 68610-06091

https://www.amazon.com/gp/aw/d/B07S8NFY99

My plan is to ream those out and sandwich it between two pieces of steel using two heavy duty large bolts and nylon lock washers.

Still concerned about it rubbing against the window rail.

Avoiding a welding job as that seems to be astronomically expensive here.

 

I reamed out the door catch and got some stainless steel 1/4" hardware. Will work it out this weekend and update.

 

Installed this Camry door check and it nicely clears the window rail and I was able to install it with 1/4" bolts and nylon nuts. As you can see I trimmed 2 large fender washers.

Recommend this approach!