Replacing The Fuel Door On A Toyota Tacoma

If you're looking to replace the fuel door on your 3rd Gen Toyota Tacoma, you've come to the right place. This guide will walk you through the process step-by-step, so you can get your Tacoma looking and functioning like new again. While it may seem like a daunting task, replacing the fuel door is actually a fairly straightforward process that can be completed with some basic tools and a little elbow grease. So, whether your fuel door is damaged due to rust or bent out of shape, read on to find out how to change it.

Drilling out the two aluminium rivets with a 1/4 bit

First, gather your tools and materials. You'll need a drill, a 1/4" drill bit, safety goggles, gloves, and a pop-rivet gun. It is imperative to wear safety goggles and gloves to protect yourself from any metal shavings produced during the drilling process. Ensure you have a steady hand and a firm grip on the drill to achieve accurate drilling and avoid any mishaps.

Next, locate the two aluminium rivets that secure the fuel door in place. Position the drill bit directly over the centre of one of the rivets. Start drilling slowly and with moderate pressure to create a pilot hole. Gradually increase the speed and pressure as the drill bit penetrates the rivet. Use a steady and controlled motion to avoid slipping or damaging the surrounding area.

Once the first rivet is completely drilled out, repeat the process for the second rivet. Ensure that you maintain a firm grip on the drill and apply consistent pressure to achieve a clean and precise hole. Take your time with this process, as rushing may result in an uneven hole or damage to the vehicle's body.

After drilling out both rivets, use the pop-rivet gun to install the new fuel door. Follow the manufacturer's instructions for the proper use of the pop-rivet gun. Ensure the new fuel door is securely attached and sealed before closing the fuel door compartment.

Finally, test the new fuel door to ensure it opens and closes smoothly and securely. This process may vary depending on the specific model of your 3rd Gen Toyota Tacoma, so it is always recommended to refer to your owner's manual or seek advice from a qualified mechanic if you have any doubts.

Installing new fuel door with two new rivets

To install a new fuel door with two new rivets, you will need to first drill out the two existing aluminium rivets. Use a 1/4" bit to drill out the old rivets. You can then install the new fuel door using a pop-rivet gun and two new rivets. Make sure to use the correct rivets for your model of Toyota Tacoma. The part number for the rivets is 90269-06017 13-741. These are specialty aluminium rivets with a diameter of 6.3mm (1/4") and a flange diameter of 13mm (1/2"). The grip range is 1.6-4.8mm (1/16-3/16").

It is also important to remember to apply sealant when installing the new fuel door.

Using a pop-rivet gun

To change the fuel door on a 3rd Gen Toyota Tacoma, you will need to use a pop-rivet gun to drill out the old rivets and install new ones. Here is a step-by-step guide on using a pop-rivet gun:

Selecting the Right Rivets:

Before you start, it is important to choose the right type of rivets for your project. There are different types of rivets available, such as blind rivets, solid rivets, multi-grip rivets, sealed rivets, and interlock rivets. Consider the specific requirements of your project, such as the weight-bearing capacity, the need for a water-tight seal, or the type of material you are joining.

Drilling the Rivet Hole:

Using a standard twist drill, create a hole in your material that matches the size of the rivet you will be using. The size of the hole will determine the appropriate rivet size. For example, a 5⁄32 inch (0.40 cm) hole requires a number 21 drill bit, and you will need a 5⁄32 inch (0.40 cm) rivet with the proper nozzle attachment. Always wear safety goggles, gloves, and a safety jacket when operating power tools.

Attaching the Nozzle Attachment:

Your pop-rivet gun will come with different nozzle attachments located in the handle. Choose the appropriate nozzle attachment based on the size of your rivet. Use the small wrench provided with the gun to remove and attach the nozzle attachments. Turn them counterclockwise to remove and then gently screw the new attachment into the nozzle by turning it clockwise with your hand.

Loading the Rivet into the Gun:

Slide the longer side of the rivet into the nozzle of the gun. The rivet has two parts: the body (tubular in shape) and the setting mandrel (the long side). Ensure that the shorter side of the rivet is the end that will be inserted through the holes in the materials you are attaching.

Positioning the Rivet:

Place the rivet through the holes in both materials. Make sure that the shorter side of the rivet is fully through the holes and that your gun is parallel to the piece of metal. Apply pressure to the gun so that the large end of the rivet is tightly pressed against the metal. Hold the gun steady with your thumb on top.

Squeezing the Trigger:

While maintaining steady pressure, squeeze the handle trigger of the gun. Each squeeze will pull the metal pin in the rivet through the body. Continue squeezing until you hear a pop and the pin snaps. This means the rivet has attached and secured both materials.

Final Steps:

Once the rivet is in place, discard the pin (the longer side of the rivet). If you make a mistake or need to remove the rivet, you can use an electric drill or a rivet removal tool. Always follow safety precautions when using power tools and working with metal.

Applying sealant

When replacing the fuel door on a 3rd Gen Toyota Tacoma, it is important to apply sealant to the fuel filler lid. Here is a detailed guide on how to apply sealant:

Before applying the sealant, ensure that the surface is clean and free of any dirt, grease, or debris. Use a suitable surface or engine cleaner to prepare the area. It is crucial to work quickly as you apply the sealant, as you only have a short window of time before it starts to set.

Select an appropriate sealant or "Formed in Place" gasket sealer for the sealing surface of the fuel door. Apply a thin, even coat of the sealant to the entire sealing surface, making sure to cover all areas that will be in contact with the fuel filler lid. Work methodically to avoid missing any spots.

After applying the sealant, you will have a limited time to install the fuel filler lid before the sealant starts to cure. Refer to the manufacturer's instructions for the exact time frame, as it may vary depending on the type of sealant used. If you do not install the lid within the specified time, you will need to scrape off the sealant and start the process again.

Once the fuel filler lid is in place, use a pop-rivet gun to install new rivets and secure the lid firmly. Ensure that the rivets are properly aligned and seated before tightening them. Finally, inspect your work to ensure that the fuel door is securely attached and that the sealant is providing a tight seal.

By following these steps and working with care, you can effectively apply sealant when replacing the fuel door on your 3rd Gen Toyota Tacoma.

Purchasing a new fuel door

When purchasing a new fuel door for your 3rd Gen Toyota Tacoma, there are a few things to keep in mind. Firstly, it is important to ensure that you are buying a fuel door that is compatible with your specific vehicle model and year. Fuel doors are model-specific, so you need to make sure you get the right one for your Tacoma.

You can start by checking online retailers that specialise in car parts, such as ToyotaPartsDeal.com, which offers a wide range of OEM Toyota Tacoma fuel doors. When shopping online, it is important to verify the compatibility of the fuel door with your vehicle. Most websites will have a tool that allows you to select your vehicle model and year to ensure the correct fit.

For example, if you own a 2005-2016 Toyota Tacoma with a 4-cylinder 2.7L or 6-cylinder 4.0L engine, you would want to look for part number 77305-04904 or 77305-04905. On the other hand, if you own a 2015-2022 Toyota Tacoma with a 4-cylinder 2.7L or 6-cylinder 3.5L engine, you would need part number 77305-04080 or 77305-04090.

It is also worth considering the different styles and finishes available for your new fuel door. You can choose a design that matches the exterior of your Tacoma or adds a unique touch to it. Some fuel doors also come with a locking mechanism for added security.

Additionally, it is beneficial to look for a fuel door that comes with a warranty. This will give you peace of mind in case there are any issues with the product. Websites like extremeterrain.com offer a range of affordable fuel doors with different styles and finishes, and they also provide free delivery for orders over a certain amount.

Finally, when purchasing a new fuel door, don't forget to factor in the cost of any additional parts or tools you may need for the installation process, such as rivets or a pop-rivet gun.

Frequently asked questions