[Dick Larimore]

If you should ever pull the lever to open the Prius gas cap door to fill the tank and it does not pop open, there is an easy solution to getting the door open. A second person is not needed to hold the lever while you "tease" the door open. Simply pull the driver's seat belt down from the door pillar and hook it over the gas door lever at the base of the seat. Pull on the seat belt allowing the excess length to retract. The seat belt will then hold the lever up. Any number of objects can be used to gently pry the door open (credit cards, paper clip, the pocket clip from a BIC pen, etc.).

Note that the hinges of the gas door have a lot of friction to movement due to the tight fit of the hinge around the wire pins and paint runs in the hinge joint. Use a light oil to lubricate the hinge and "exercise" the joint to keep it moving freely. This will minimize the amount of spring force required to pop the door open in the first place.

 

[john1701a]

A preventative squirt or two of WD-40 is all that's needed.

Then you won't ever need that seat-belt suggestion. Though I must admit, that's pretty creative.

When my gas door stuck, having someone hold the lever (you'll find lots of volunteers willing to see a hybrid up close) then pushing on the door popped it open. I didn't need to stick anything inside to pry it loose. Later I discovered the hinges had simply dried out from the winter's generous doses of sand & salt. So your suggestion of using a bit of oil is right on.

 

[fleubis]

I had the same problem with my 2001 Prius, and appear to still have the same problem. The spring they use for holding allowing the gas tank lid to open is underpowered. Every time I fill up I take a couple seconds and bend it out a little bit. John suggests installing a small spring. I'm sill looking for the right thing. So here is one tiny little thing they still haven't fixed.

 

[owen rubin]

I had the same problem with my 2001 Prius, and appear to still have the same problem. The spring they use for holding allowing the gas tank lid to open is underpowered. Every time I fill up I take a couple seconds and bend it out a little bit. John suggests installing a small spring. I'm sill looking for the right thing. So here is one tiny little thing they still haven't fixed.

I would be interested in this as well. Last night, my filler door would not open. I found the seatbelt solution above, and thank you, it worked great. :smile2:

My door problem would NOT have been fixed with a little WD-40, as the door swings very easily. That was/is not a problem (although I will add some anyway to keep it swinging free.)

It seems I also have the "spring" problem as well. That small tab of metal that pushes open the door gets pushed flat over time, and no longer pushes on the door. I too will bend it out now, but thats great right up to the point where it finally breaks off or fatigues too much. And then what?

So if someone figures out a spring solution, I would also be interested. If I come up with one myself, I will post it here.

 

[SorenLorenson]

My spring is broken clean off.

Based on a thread on Prius Chat (https://priuschat.com/threads/gas-door-spring-failure.55198/), I put a piece of foam pipe insulation (I had some of the closed cell rubber foam with its own sticky edges that I used to stick it on), to put pressure on the door to pop it out when the latch is pulled. It works so far.

Looks like the correct "Fuel Door Spring" is part number 77360-33020, and list price is $5.57.

 

[Paul Jones]

That was a pretty tricky advise. But I only rely to my WD-40 always. _____________________________________________
Towing St. Louis