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gas fill door release lever frozen, cannot fill car

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by priusrecon, Jan 31, 2022.

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  1. priusrecon

    priusrecon Member

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    Recently tried to fill up at a gas station. Could not get the fill door open. Found the gas filler door release lever frozen rock solid. Did not want to pull too hard on it for fear of breaking the plastic.

    Never had this problem before. I usually fill up about every 1 or 2 weeks. Door and release worked fine last time. It is winter here in upstate NY. It's getting to where I really need to put gas in the car now.

    How do I free this up, or at least get the filler door open without ruining it?

    Thanks,
     
    #1 priusrecon, Jan 31, 2022
  2. ChapmanF

    ChapmanF Senior Member

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    Do you know anyone with some above-freezing garage space that you have enough fuel to drive to?
     
    #2 ChapmanF, Jan 31, 2022
    PriusCamper and SFO like this.
  3. priusrecon

    priusrecon Member

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    Car sits in a warmish garage at night, abt 40-50 degr it reaches during the day. I've tried hitting the lever with a hairdryer covered by a towel and gently tapping it with a hammer after 15 minutes.

    Is there a way to draw lubrication through the cable sheath to free it up?

    And what lubes are safe on plastics?

    Thanks,
     
    #3 priusrecon, Jan 31, 2022
  4. ChapmanF

    ChapmanF Senior Member

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    Hmm, sounds less like frozen and more like, maybe, rusted.

    Might be time to dismount the lever from the floor and from the end of the cable, then use vise-grips and expanding pliers to give it a strong enough pull to get the filler door open. Then disconnect the cable at that end and either replace it, or take it to a nice ergonomic workbench and work it over for a long time with penetrating oil and then with new lube.
     
    #4 ChapmanF, Jan 31, 2022
  5. sam spade 2

    sam spade 2 Senior Member

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    I think you are working on the wrong end.
    More likely that water has gotten inside of the DOOR and frozen the latch or cable from that end.
    Try the hair dryer at that end.

    Also using a wood or plastic "pry tool" you might be able to pop the door open without doing too much damage.
     
    #5 sam spade 2, Jan 31, 2022
  6. alftoy

    alftoy Senior Member

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    Similar to this video, need to pull that side panel loose. Pic of my 2008 Prius with my side panel loose. Fuel door spring may also be corroded.



     

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    #6 alftoy, Jan 31, 2022
  7. alftoy

    alftoy Senior Member

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    You may be able to reach inside the opening right behind the tail light, reach in behind the side panel, twist the plunger latch and pull it out as in the first video. Trying to pull the top of the side panel when it is 40-50F may break the tabs, but you can try pull the top of the panel open enough to reach in to twist and pull the plunger.

    Also a closer pic of the plunger.
     

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    #7 alftoy, Jan 31, 2022
    Last edited: Jan 31, 2022
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