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Fuel Door Spring fix

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Rav4-21

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21 RAV4 XLE Premium AWD Gas
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Discussion starter · #1 ·
Anyone's Fuel Door Spring Break off...?
Little woman couldn't get it open so i had her pull the fuel door lever, while i slid a smooth piece of Cardboard in the right side and popped it open.
The Spring Clip dropped on the Floor, I taped it back with Duct Tape for a temporary fix, also left the piece of Cardboard in the car.

I believe i found the part Number.....

Spring; Spring Assembly
77360-35040
Fuel Door Spring
 
#3 ·
Mine is still in good working order. However, I did see a video of someone opening the back hatch and remove the plastic cover approximately where the gas door is located and put their hand in there and manually opened the gas door. Probably less aggravating than the cardboard idea until you can get it replaced.
 
Discussion starter · #5 ·
Uhhh Yea,
The Cable is not broken, it is the clip on the left side near the cap tethering cord, you can pull, or flip, or whatever you want but the Spring to pop the fuel door is broken...

Thanx anyway.
The Cardboard slides in n when someone pulls the lever, the door pops open, but i turned the broken spring over and used duct tape to affix it back on the back side of the door,....
I wanted to know if someone else's clip has broken..?
 
#6 ·
Mine broke a few months back. Idk if its super common, but def not unheard of. Pretty easy to replace and I had thought of getting it through Toyota warranty...but for 6 bucks i saved the hours of waiting at a dealership lol. If it breaks again or really often I might see if I can CAD on up and just 3D print it
 
Discussion starter · #8 ·
Thanx for responding,
Yes it is under warranty, they ordered a Nut on the end of the release shaft, i called them and said you ordered the wrong part...
How do you know that, i said there is only one item in the diagram of fuel door assembly, it even says spring, he said well i will order it along with the other part, i said it does Not Need A Nut...
I will take it in when they get the part in since it has an Oil Pan Gasket Leak...o_O:eek:...just a small one they say...
18,000 miles. Jeez.
I will look into that Epoxy, what did you use. Was tempted to do that but like you say, its under warranty...
Was wondering how common it is cause, they never heard of it before,...(Sure Eddie.)
I will tell you, that part is so flimsy its stupid, as you well know.
 
#9 ·
Rav4-21 said:
Thanx for responding,
Yes it is under warranty, they ordered a Nut on the end of the release shaft, i called them and said you ordered the wrong part...
How do you know that, i said there is only one item in the diagram of fuel door assembly, it even says spring, he said well i will order it along with the other part, i said it does Not Need A Nut...
I will take it in when they get the part in since it has an Oil Pan Gasket Leak...o_O:eek:...just a small one they say...
18,000 miles. Jeez.
I will look into that Epoxy, what did you use. Was tempted to do that but like you say, its under warranty...
Was wondering how common it is cause, they never heard of it before,...(Sure Eddie.)
I will tell you, that part is so flimsy its stupid, as you well know.
Click to expand...

So i put epoxy on the new one on top of where the little plastic t holds the metal spring. i cant remember what brand i used
 
Discussion starter · #10 · (Edited)
hotracer_05 said:
So i put epoxy on the new one on top of where the little plastic t holds the metal spring. i cant remember what brand i used
Click to expand...
Well ok. Was it the plastic epoxy or Metal, since it is both, i have one kind, plastic i think, i moved and some of it is in boxes.
If it was stronger id drill a tiny hole and put a bolt or rivet through it. :unsure: :giggle:
Thanx again...
Alan
 
Discussion starter · #13 ·
davebeats said:
Just had the same thing happen to me, $4 part and takes 30 seconds to change.
Click to expand...
Sorry i didnt see your post, was going through some old mail...
Dealer replaced it under warranty and refused me the part, i ordered another for a spare, what worries me if it is new and breaks, being so fragile, i can see it being extinct in about 10 yrs...

If it breaks again i will try an epoxy fix...
The woman that helped my wife at the pump hit it or something, i never go anywhere near it when i fill up...
 
#14 · (Edited)
I just opened the fuel door and the small clip popped off. I think I see where it goes. It is part 4 in the middle diagram
2006-2021 Toyota Spring; Spring Assembly 77360-35040 | Toyota Parts (mcgeorgetoyota.com)



****UPDATE, I used JB Weld, we will see if it works.

Also, I have never seen this happen on a Toyota before in a combined 500K miles and 35 years of owning Toyotas. I also only have 33K garaged miles so not much use on this part and I close the fuel door with little force. Looks like yet another design flaw.
 
Discussion starter · #15 ·
Variman said:
I just opened the fuel door and the small clip popped off. I think I see where it goes. It is part 4 in the middle diagram
2006-2021 Toyota Spring; Spring Assembly 77360-35040 | Toyota Parts (mcgeorgetoyota.com)



****UPDATE, I used JB Weld, we will see if it works.

Also, I have never seen this happen on a Toyota before in a combined 500K miles and 35 years of owning Toyotas. I also only have 33K garaged miles so not much use on this part and I close the fuel door with little force. Looks like yet another design flaw.
Click to expand...
I posted the link to the part in #1 and several others have had the same problem... 😧
 
#16 ·
Rav4-21 said:
Uhhh Yea, The Cable is not broken, it is the clip on the left side near the cap tethering cord, you can pull, or flip, or whatever you want but the Spring to pop the fuel door is broken... Thanx anyway. The Cardboard slides in n when someone pulls the lever, the door pops open, but i turned the broken spring over and used duct tape to affix it back on the back side of the door,.... I wanted to know if someone else's clip has broken..?
Click to expand...
 
#17 ·
Rav4-21 said:
Uhhh Yea,
The Cable is not broken, it is the clip on the left side near the cap tethering cord, you can pull, or flip, or whatever you want but the Spring to pop the fuel door is broken...

Thanx anyway.
The Cardboard slides in n when someone pulls the lever, the door pops open, but i turned the broken spring over and used duct tape to affix it back on the back side of the door,....
I wanted to know if someone else's clip has broken..?
Click to expand...
Mine did yesterday. It wasn’t touched or anything. I was filling up the gas and noticed the silver part fall off and I picked it up and looked where to belong and the cheap brittle plastic that the metal clip sits on was just disintegrating. I have a pretty new car it’s crazy!
 
#19 ·
Reminds me of my 1'st Prius an '04, it had headlight levelers in the rear under the car that had a spring that often rusted, I used a spring from a pen and sealed everything up, it's like Toyota is penny wise and pound foolish, for example in a 23 rav4 prime with the advanced package, the passenger seat doesn't have a lumbar cushion, and to go on, the upgraded JBL speakers have 1/2 oz magnets, (just put in Infinity Reference Hugh magnets), but....48 miles of pure electric on Dec 1'st in NH is nice, so, what ya' make on the popcorn ya' lose on the peanuts.
 
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