I found a large binder clip was a perfect replacement for the broken hinge. I cut the hinge pin off. Cut off a section of the binder clip and screw it to the inside of the hinge frame. I used the chrome handle as the replacement pin too.
Thank you for the fine community service of posting this video. A huge gesture to those in need. I performed exactly as shown and was thankful to know ahead of time what to do. Half-inch long, quarter inch bolts.
For those who have the Predawn Mica Gray (1H1) color. I bought a new replacement fuel filler door. Comes with the hinge of course. And its black, needing to be painted. $35 from my local dealer. I bought the dark shadow gray metallic Dupli-color, as well as the Clear spray from Autozone. It comes closer than any other color and looks great. Its advisable to do a mod on the spring they used for the button switch. They used such a strong spring that it puts way too much tension against the door. Which is what breaks the top hinge. You can take out the button assembly and grind the spring mount to take some tension off. Or just plan to replace the door every time it breaks. Your choice.
The fact that 52 thousand people have viewed this indicates a systematic safety issue. You cannot exit left side of vehicle if this breaks......Toyota should recall.....
First time welder here. Thanks for posting this video. This happened today on my 2012 Sienna with 90K. Getting a Titanium 225 inverter stick welder (DC) from Harborfreight and based on my research I think the 6013 EN rod to reduce the penetration of the weld. Can someone please chime in? I will obviously try and practice on some thin metal sheets first as I don't want to burn a hole through the fuel door. I'm assuming the reason you drilled out the holes was because the pin was bent and it wasn't turning freely. Mine seems to turn freely so unless there's another reason for drilling the holes out I'm going to skip that part. Also, I didn't see you put the black plastic piece that attaches to the pin back. Thanks again for the video.
Got the welder 2 days ago. Practiced a bit. In short, I sucked. But, I got the job done. For those that need to know, I used 3/32 6013 DCEP at about 55amps. I tried using 1/16 6013 DCEN and I think maybe I didn't have enough amps. My initial attempts (3) kept not sticking at all. After using the 3/32 DCEP, I knew it would be hotter and was concerned about burning through. I ended up almost burning through the hinge rod itself. Thankfully I still have quite a bit of meat left on there. In hindsight, I should have practiced more but it was kind of hard trying to find the same kind of thin steel to practice on. I only had 1/8" scraps from a metal shop that they gave me. Yes, I cleaned it down to bare metal and washed with acetone. Anyways thanks to the OP for posting this. I got into welding because I refused to pay the dealer $.01 to do anything. They suck. And you don't! Thank you!
I also used a cut-off wheel on a dremmel and carefully cut a notch into the tension bar for the door sensor spring. (2) 15mm nuts hold it in place (saw that on another video) and that reduces the amount of pressure on the hinge when you close the door. It's a design flaw as the stock connection to the hinge rod isn't even a weld, it's just a piece of bent sheet metal and thus the weak point is on the top of the hinge.
Thanks, love to see the same challenges I have usually. I will have to try this... the part costs $66 alone, plus paying someone else to rivet it in. I wish I had rivet gun to use.
Probably would be cleaner and less fuss with rivets. Also, capture of old rivets from inside could somehow be accomplished with a vacuum running while drilling or use of large cow magnets on strings assuming the rivets were steel.
Thanks for posting, I'm having the exact same problem with my Sienna...Toyota really messed up here. I did think something was wrong with the video at first with no sound starting until half way through...was that on purpose?
I have a broken hinge on my 2007 Corolla. Didn't realize the top and bottom bolts were actually rivets and I'll have to drill through em. Also didn't know about the metal ring around the rubber as I was scratching my head on how to get behind the wall originally thinking they were bolts screwed in from the inside out. Still....I'm thinking I need a whole new fuel door as again mine the hinge just broke off and I don't have a Tig welder,heh.
This happened to my 2011 Toyota Sienna. I have the Toyota Certified Platinum warranty. I brought my van in to the dealer and they told me it's not covered by my warranty. They directed me to go to a "collision" shop to have it fixed.
My 2015 sienna have same problem dealer replace it under warranty but after 4 years failed again I can smell many thousand more mean is a bad design by manufacturer thanks Toyota bcz slide door sensor is inside gas door if gas door is open or broken sliding door don't work
I just want to say that video you made about American Greetings was uncalled for, why are you opening your wife’s mail and if it’s so upsetting why did she make the video about it is it just upsets you
Thanks for this. Just fixed the fuel door on my '11 Sienna. And for those asking...I used 1/4 in 20 x 3/4 in round head machine screws.
I found a large binder clip was a perfect replacement for the broken hinge. I cut the hinge pin off. Cut off a section of the binder clip and screw it to the inside of the hinge frame. I used the chrome handle as the replacement pin too.
Will you kindly share a picture of your fix?
Thank you for the fine community service of posting this video. A huge gesture to those in need. I performed exactly as shown and was thankful to know ahead of time what to do. Half-inch long, quarter inch bolts.
Same issue with my 2007 Prius. Thanks for the video, gives me some ideas on how to fix it myself.
For those who have the Predawn Mica Gray (1H1) color. I bought a new replacement fuel filler door. Comes with the hinge of course. And its black, needing to be painted. $35 from my local dealer. I bought the dark shadow gray metallic Dupli-color, as well as the Clear spray from Autozone. It comes closer than any other color and looks great. Its advisable to do a mod on the spring they used for the button switch. They used such a strong spring that it puts way too much tension against the door. Which is what breaks the top hinge. You can take out the button assembly and grind the spring mount to take some tension off. Or just plan to replace the door every time it breaks. Your choice.
Thank you for the info, can you elaborate with a video on how you removed the tension?
My 2003 Avalon also has this problem. Finally rusted off yesterday. Thx for info!
The fact that 52 thousand people have viewed this indicates a systematic safety issue. You cannot exit left side of vehicle if this breaks......Toyota should recall.....
I agree same issue with me and if it were to be recalled do to customers like us complaining who would we need to complain to?
It just happen to mine 2011 sienna
Yeah the sensor is too stiff. It keeps breaking the door.
First time welder here. Thanks for posting this video. This happened today on my 2012 Sienna with 90K.
Getting a Titanium 225 inverter stick welder (DC) from Harborfreight and based on my research I think the 6013 EN rod to reduce the penetration of the weld. Can someone please chime in? I will obviously try and practice on some thin metal sheets first as I don't want to burn a hole through the fuel door.
I'm assuming the reason you drilled out the holes was because the pin was bent and it wasn't turning freely. Mine seems to turn freely so unless there's another reason for drilling the holes out I'm going to skip that part.
Also, I didn't see you put the black plastic piece that attaches to the pin back.
Thanks again for the video.
Got the welder 2 days ago. Practiced a bit. In short, I sucked. But, I got the job done. For those that need to know, I used 3/32 6013 DCEP at about 55amps. I tried using 1/16 6013 DCEN and I think maybe I didn't have enough amps. My initial attempts (3) kept not sticking at all.
After using the 3/32 DCEP, I knew it would be hotter and was concerned about burning through. I ended up almost burning through the hinge rod itself. Thankfully I still have quite a bit of meat left on there. In hindsight, I should have practiced more but it was kind of hard trying to find the same kind of thin steel to practice on. I only had 1/8" scraps from a metal shop that they gave me.
Yes, I cleaned it down to bare metal and washed with acetone.
Anyways thanks to the OP for posting this. I got into welding because I refused to pay the dealer $.01 to do anything. They suck. And you don't! Thank you!
I also used a cut-off wheel on a dremmel and carefully cut a notch into the tension bar for the door sensor spring. (2) 15mm nuts hold it in place (saw that on another video) and that reduces the amount of pressure on the hinge when you close the door. It's a design flaw as the stock connection to the hinge rod isn't even a weld, it's just a piece of bent sheet metal and thus the weak point is on the top of the hinge.
Toyota issued a customer confidence program to cover the fuel filler door hinge and pin for 10 years regardless of mileage.
Nice but I don't have time to waste at the dealer. Plus I got more tools. :D
@@checkman007 they stopped it last year and many were not aware of this!
This worked great. Added a cap nut to the "safety" plunger to take the pressure off.
A Cap Nut ??? What is this?
I used four of 22-gauge wires plus a zip tied to strap it. It works fine for me. When i have time i will remove it and use welder to fix it.
Thanks, love to see the same challenges I have usually. I will have to try this... the part costs $66 alone, plus paying someone else to rivet it in. I wish I had rivet gun to use.
The pin on my Lexus IS300 snapped off. Bought a new fuel door off eBay and did the same procedure in the video. So far so good.
I need to replace the fuel door on my 2004 sienna, I think lock washers would be good to prevent the nut from loosening later.
That's what I used. They cost more, but they will not loosen with the vibration .
Nice, thanks! At the end forgot to put in the little black plastic thing to hold it open...
I was like :) hey, I can do this until 8:27 :( I can't weld!
I have the same problem, but my van's color is silver. It is worth to buy welding machine?
Thanks for the vid!
Mine just fell off my 01 celica last night. Now me n dad can fix it
Probably would be cleaner and less fuss with rivets. Also, capture of old rivets from inside could somehow be accomplished with a vacuum running while drilling or use of large cow magnets on strings assuming the rivets were steel.
this all happen because the sensor on the upper left corner is so hard to press what cause the hinge to break. Good video thanks
Thanks for posting, I'm having the exact same problem with my Sienna...Toyota really messed up here. I did think something was wrong with the video at first with no sound starting until half way through...was that on purpose?
What is the hinge part#? I can only find the whole for assembly and don't feel like paying for everything when I have a perfectly good door.
I need one too. Did you get an answer
Got my hinge at the local junker. I was lucky and not charged for it.
Curious why you didn’t try to weld it without removing the door?
Fuel vapors and welding dont mix
@@brandon4601 Yup. Welding gasoline vapors is a real bad idea. Someone ask me how i know :)
Use a bigger drill bit on the rivets and you don't have to chisel. Nice fix, unless you don't have a tig welder.
Good idea. Welding inches from potential gas vapor is always a good idea.
I have a broken hinge on my 2007 Corolla. Didn't realize the top and bottom bolts were actually rivets and I'll have to drill through em. Also didn't know about the metal ring around the rubber as I was scratching my head on how to get behind the wall originally thinking they were bolts screwed in from the inside out. Still....I'm thinking I need a whole new fuel door as again mine the hinge just broke off and I don't have a Tig welder,heh.
Thanks for your idea..... I fixed.... :)
Nice. Same happenned to my Celica 2000. I can't believe the shitty design they did on almost all Toyotas on this part
Thanks, worked like a charm
I have exactly same problem on my Sienna 2011. Thanks for posting, I will try to fix mine.
Same issue with my 2011 where you able to fix it and if so was it more complicated than it looked?
Same issue on my 2011. Was the hinge welded back together after removed or was a new one put in?
Jeeez lube both hinge points, use vice grips rotate grips whike lubing less time and work!
Whats size was the bolt & nut? I need to do this on my corolla.
Dzan28 I have to do this on my Corolla now. Did you find out what size bolt and nut?
This happened to my 2011 Toyota Sienna. I have the Toyota Certified Platinum warranty. I brought my van in to the dealer and they told me it's not covered by my warranty. They directed me to go to a "collision" shop to have it fixed.
Yea. It’s not covered
Good Job!
Thanks. (note" "weaken")
Thank you!
Got a gold 2011 sienna that just broke in the same place
Same problem here
Easier to use a vice grips instead of channel lock pliers
what is the size of the bolt used here?
Need it to fix the same problem.
thank
My 2015 sienna have same problem dealer replace it under warranty but after 4 years failed again I can smell many thousand more mean is a bad design by manufacturer thanks Toyota bcz slide door sensor is inside gas door if gas door is open or broken sliding door don't work
Nicest owner ever :) , I would not be happy with that result, :)
Someone tried to get into my gas tank and ended up breaking my hinge, now I can’t open my car door
Dude...the chisel really? And why pop the gas cap tab off? Unscrew the gas cap off with it and pop a rag in to block it.
Would jb weld fix the hinge?
I came across this and will try Loctite metal on my POS Toyota gas door! ruclips.net/video/bM4IGweHT2k/видео.html
Aaron Nelson how’d that work out?
No sound for first few min?????????
Sr look kho Gaya hai to
I just want to say that video you made about American Greetings was uncalled for, why are you opening your wife’s mail and if it’s so upsetting why did she make the video about it is it just upsets you