Well, its gotten to the point where I have to jiggle the lock for a few minutes before I can get the door open. Once open, it may work again the first try or it could take another couple of minutes to get it open. Doesn't matter if the key is in one way or flipped.

Does Toyota sell just the lock and a key or do I need to replace the whole door/lock/new key? Any idea's? Maybe find a door that doesn't need to be locked?

 

you might be able to remove the lock and take to a lock smith and they could rebuild it with new pins and springs.
dose your fuel door lock also have a inside latch to open it ?

 

When you say inside latch, you referring to inside the truck itself or inside the locking door? If inside the truck, no.

 

I do not want to assume anything, so have you tried spraying the lock assy down with some lithium grease? That might restore the components to their original performance.

If you are concerned with the door becoming stuck and not opening you can bend the tab on the lock and it will not contact the housing on the fender. Probably though your door would not stay closed.

 

Yes toyota does sell just the lock set for the fuel door, it should come with a key set (mine did) but it will most likely not match the rest of the truck. I will post the part # for you later today (don't have it on me just now). If you have an original lock set key in good condition a locksmith should be able to re-code the new lock to match for around $20-30 bucks.
If you need a new original key the dealer may be able to use your VIN to get the original key code and cut you a key from that but there is no guarantee that the data is still available since Toyota usually only keeps that info in there database for about 10yrs or so... I got lucky they still had it, dealer was surprised as well...
You can remove the lock set relatively easily there is only a clip holding the lock on, but the door will fly open going around turns or when backing up.
A locksmith may be able to re-build the lock as well but i have no idea what that would cost...

 

When it was freezing cold and I was driving across the country the same thing happened to me. In frustration, I used my knee and dented the gas door a little. I figured out that my problem was that I was using a copy of my Toyota key and not the original one that came with the truck. Since using the original equipment/key, I've had no problems. It's a little stiff but at least I don't hurt my knee anymore. A week ago I brought the graphite lube out of the tool box and like a miracle, it cured all of my locks sticking and age. Graphite is the fountain of youth for locks. Get a tube and squirt some in every tumbler you have time for, you will be amazed!

 

yeah, i would try lubing it up before replacing it, both my door locks and the fuel door lock were incredibly sticky when i got the truck, like almost to the point of not working at all. I just opened the fuel door and put some machine oil on and around the lock mechanisms, and squirted a little in both door keyholes- they all work perfectly fine now

 

Here are the fuel door lock part #s as promised
the lock - 69058 w/set of keys
the plastic lock "pad" - 69513
the metal retainer - 69511 or 69581 (either # may be current not sure which)
** note all 3 parts are ordered seperately and all three are needed for lock install.

Further info... a full set of locks would be part #69503 incl. 1 set of keys
individually the part #s are
pax door - 69051 w/set of keys
fuel door - see above
drv. door - 69052 w/set of keys
ign. - 69057A w/set of keys
** if purchased individually you will have to get the locks re-coded to match by a locksmith. If you need more then 2 replaced it might be worth ordering the whole set to simplify everything**

 

I had the same problem...so I did an easy mod.
Sorry I am out of town right now otherwise I would post a pic.

Mine is all rusty and was getting worse and worse, I hit it with PB blaster and it seemed to make it even worse, now I am sure it would never be opened by a key again, even the original key.

So I tied the spring mechanisim up so it wont latch anymore, and stacked a few strong magnets around. There is a small gap between the magnets and door and it hold the door closed very well. I still use my key to open it by wedging my key in the corner and popping it open. It still looks locked to theives and I dont have to worry about bending another key.