Has anyone actually fixed the misaligned fuel door?

My fuel door is misaligned. It'll pop open with the lever just fine, but opening it up, even when pulling on it to avoid scraping, I'll scrape it against the body. Is my only real option getting a new fuel door? Or has someone actually figured this out, so I can stop it from scraping, so I can just touch it up?

 

Lol, how do we have the same issues. Still looking into what I can do to stop it. Wish the fuel door was attached with screws like my old Tacoma instead of rivets so I could remove it and modify it.

 

Didn't realize this was a wide-spread issue, would be as easy as drilling out rivets, replacing with screws for the adjustability, didn't have this issue on my 04 v6, but definitely have it on my 03 v8 Once I get to a point where I have tinker time I'll fix it and put the fix up here, but that's not going to be really soon/quick.

 

FJ guys have this problem too

 

Yep. Have an '06 with the same problem.

 

My 08 Urban Runner has same problem.

 

ive just been scratching my paint for 6 years, i think im numb to it

 

both my runners have and I'm wanting to stop it now

 

same thing for mine too, thinking the same thing, drill out rivets, add washer behind it for that clearance not to scrape and then screw or rivet it back on.

how can you get access to the back side of it? just in case I want to use screws with nuts behind it

well hell then, shouldn't there be a recall to fix it? scratching paint finish has to be a problem with rust at some point?

 

I'll look more into it this weekend since it seems to be a common problem. My 04 did not have this issue.

 

On my former '14 Taco, I just put a plastic putty knife in the gap at the hinge, and bent the door away from the hinge.

Steve

 

mine creaks really bad when opening it, is that the issue at hand?

i just thought the previous owner bent something and i just deal with it. didn't know it was a common issue.

 

that's the sound, if you see can see between the door and the body, it'll prob be really scraped up

 

Fixed mine this past weekend, not for the faint of heart people, I ended up taking a plastic rod about 3/8" in diameter rounding the tip and I placed it on the area wear the fuel door was rubbing and I tapped it a few firm times with a hammer.

 

just to space out the body line and the fuel door?

 

Yes

 

filled up at a full service gas station today and the attendant cringed opening the door. after 6 years i might try to fix it

 

New factory fuel doors are about 60 bucks from some of the online parts sources. It's very easy to simply drill out the 2 rivits on the old door. Attach the new door with 2 pan head phillips stainless screws with a serrated nut, or nut with lock washer. Gently pull back the rubber material around the fill neck for access. The fix is cheap and easy to do.....no more creaky, mis-aligned door rubbing on your paint!

 

Is this painted or not?

 

The fuel doors come through in primer. You can have them painted to match....I installed mine "as is". Being that it's now attached with screws, I could take it off anytime and have it painted.

 

I messed with mine while at a gas station the other day, completely fucked it up lol. IT rubs worse now and having issues with the release working now, DOH. I'll actually have to remove it and fix it, probably just remove, reattach with screws and paint with a paint pen and clear it.

 

That's the boat i was in, I just put a towel over it and punched it reasonably soft a few times tbh. It only rubs beyond open 90* now.

 

Yes, bought a new one. Total cost for rivets and door was less than $80 and I just bought spray paint in my color code online. Then cleared it and was done.

 

forgot about this thread... a few months ago i smeared some lithium grease along the hinge and between the door and where it scrapes and... no more squeak! i'll probably have to reapply occasionally but that's fine with me.

specifically:

 

Glad Im not the only one, with this issue.

 

Sorry to revive an old thread. I have the same issue with my 04 4Runner. I bought a new door, painted it but I want to know from the guys that replaced the door, what did you do about the little spring that pops it open, there is none on my new door and I can't quite figure out how to get the old spring out and on to the new one...