Gas tank release lever is rotten!

harno · Feb 3, 2018

My Gas tank release lever is totally rotten and corroded.

Last time I tried to pull it, in order to open the "gas fill door", it did bend upwards and it was real hard to get the "gas fill door" open. Does anyone know a fix?

I assume I might have to replace the lever, but does anyone know how I could lubricate the "wire" that actually opens the "gas fill door"?

There might be proper words in English to describe the problem, but I hope you still understand what I'm talking about.:wink

Many Thanks in advance!

Harno

pico · Feb 4, 2018

harno said:
There might be proper words in English to describe the problem,

There are NO polite words in English to describe the horrible design of the fuel door release. None.

Chrometiphippy · Feb 5, 2018

Yep...totally agree...aside from the lack of a proper cupholder (I drive for a living, yes this is a big deal) the fuel door release is a source of much wailing and gnashing of teeth. Here in the snowy barren wasteland that is Northwester Pennsylvania, I've taken to A: open the fuel door whilst it's warm (enough) to open or B: dump a glass of hot water on the offending release lever and hope the ice melts and the door opens afore the fool thing re-freezes.
Hopefully someone wiser than I (which is most of the population) has an answer, because I'd like to hear it

Hippy

harno · Apr 30, 2018

It's unfortunate, but obviously no one has a FIX for this problem ....or.... does anyone have??

Roundabout · Apr 30, 2018

To lube the wire is about a 30 minute job, but when most first look at the job they think it will be too hard! Unless the cable is in really bad condition it is an easy job.

Get some light machine oil or sewing machine oil with a small spout so you can put a few drops on the cable by the sheath opening at both ends of the cable and start pulling the cable in and out to slowly work the oil along the length of the cable. Every few minutes put another drop or 2 on the high-end of the cable. After 10 of 15 minutes you will have worked the oil through the length of the sheath.

To get to the far end of the cable you need to remove the big plastic panel that goes from the windows to the floor in the back of the car. 14 screws and one 14mm bolt hold the panel in place, and it is actually easy to remove and replace the panel.

Chrometiphippy, sounds like you need some weather-tech type floor-mats, they are deep and hold a lot of water yet they are easy to remove and dump when full.
I didn't like having the mat go under the pedals so I turned the drivers-side one around so the pedal part curves up the front of the seat, stopping some of the migration of stuff under the seat.

harno · May 2, 2018

Thanks "Roundaboud" !

I will give it a shot ;-)

Markm0311 · Jan 27, 2019

For anyone doing this job it's pretty easy.

I ordered the OEM part: 77306-0R020

1. Remove the drivers side door sill plate
2. Remove all 4 bolts that hold the drivers side seat down - be careful when you pull the plastic pieces off that cover each of the bolts that hold the seat down; you should push down and pull away at each side of the plastic piece as to not break the "prongs"
3. DON'T remove the seat just lean it back
4. Pull the carpet just a little bit towards the center console so you can have some slack to pull the carpet out and over the handle itself
5. One bolt holds the release lever in place. Remove it and then remove the cable
6. Replace with the new part
7. Reassemble

sal222 · Jun 29, 2019

Markm0311 said:
For anyone doing this job it's pretty easy.

I ordered the OEM part: 77306-0R020

1. Remove the drivers side door sill plate
2. Remove all 4 bolts that hold the drivers side seat down - be careful when you pull the plastic pieces off that cover each of the bolts that hold the seat down; you should push down and pull away at each side of the plastic piece as to not break the "prongs"
3. DON'T remove the seat just lean it back
4. Pull the carpet just a little bit towards the center console so you can have some slack to pull the carpet out and over the handle itself
5. One bolt holds the release lever in place. Remove it and then remove the cable
6. Replace with the new part
7. Reassemble

View attachment 123179

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View attachment 123183

Where can I order one of these release handles from and how much do they cost? I have 2002 RAV4. Thanks.

Mick Hatzo · Jun 29, 2019

That depends on where in the world you are.
Search google for part numbers "77306-0R020" and "77306-32020".
Prices range from 20 to 30 dollars.
For example: https://www.toyotapartsdeal.com/oem/toyota~lever~sub~assy~fuel~lid~lock~open~77306-32020.html
and
https://toyotaparts.mcgeorgetoyota.com/oem-parts/toyota-release-lever-773060r020

sal222 · Jun 29, 2019

Thank you for your kind reply. I am located in New Jersey, USA. Ebay has it, but it is so expensive. I will try the website you provided. ????

s.c.vollick · Nov 20, 2022

Markm0311 said:
For anyone doing this job it's pretty easy.

I ordered the OEM part: 77306-0R020

1. Remove the drivers side door sill plate
2. Remove all 4 bolts that hold the drivers side seat down - be careful when you pull the plastic pieces off that cover each of the bolts that hold the seat down; you should push down and pull away at each side of the plastic piece as to not break the "prongs"
3. DON'T remove the seat just lean it back
4. Pull the carpet just a little bit towards the center console so you can have some slack to pull the carpet out and over the handle itself
5. One bolt holds the release lever in place. Remove it and then remove the cable
6. Replace with the new part
7. Reassemble

View attachment 123179

View attachment 123181

View attachment 123183

Thanks for posting this! I just did this replacement and it worked great!

s.c.vollick · Nov 20, 2022

Markm0311 said:
For anyone doing this job it's pretty easy.

I ordered the OEM part: 77306-0R020

1. Remove the drivers side door sill plate
2. Remove all 4 bolts that hold the drivers side seat down - be careful when you pull the plastic pieces off that cover each of the bolts that hold the seat down; you should push down and pull away at each side of the plastic piece as to not break the "prongs"
3. DON'T remove the seat just lean it back
4. Pull the carpet just a little bit towards the center console so you can have some slack to pull the carpet out and over the handle itself
5. One bolt holds the release lever in place. Remove it and then remove the cable
6. Replace with the new part
7. Reassemble

View attachment 123179

View attachment 123181

View attachment 123183

Thanks for posting this. I just did this replacement and it worked great!

PSchof · Jan 19, 2024

Markm0311 said:
For anyone doing this job it's pretty easy.

I ordered the OEM part: 77306-0R020

1. Remove the drivers side door sill plate
2. Remove all 4 bolts that hold the drivers side seat down - be careful when you pull the plastic pieces off that cover each of the bolts that hold the seat down; you should push down and pull away at each side of the plastic piece as to not break the "prongs"
3. DON'T remove the seat just lean it back
4. Pull the carpet just a little bit towards the center console so you can have some slack to pull the carpet out and over the handle itself
5. One bolt holds the release lever in place. Remove it and then remove the cable
6. Replace with the new part
7. Reassemble

View attachment 123179

View attachment 123181

View attachment 123183

Where did you get that part number? i tried it and it won't work

iowagold · Jul 3, 2025

The lock is the hold in latch

Gas tank release lever is rotten!

harno

pico

Chrometiphippy

harno

Roundabout

harno

Markm0311

sal222

Mick Hatzo

sal222

s.c.vollick

s.c.vollick

PSchof

iowagold

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