How to Remove a Locking Fuel Cap without a Key

How to remove a locking fuel cap if you’ve lost the key or if that lock is seized. When I purchased this Tacoma, it had been sitting for a while, before I purchased it and even before I put it on the road. The door on the lock was seized but did manage to get it loose just before I made this video. You may have experienced a seized lock or you lost the key.

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Tools/Supplies Needed:
-large interlocking pliers
-self tapping screw
-screw gun
-replacement fuel cap

Procedure:
The cap can be installed and tightened without the key, however, it can’t be removed after without that key. The exterior case just slips while the threaded portion stays stationary.

Large interlocking pliers can be used, simply grab tightly onto the outside cap, let the outside plastic cap clamp down on the inner portion which will allow you to turn the cap. However, this doesn’t always work as the cap may sit in a tight spot, now allowing room for the pliers or movement. And you can’t reuse the cap for temporarily until a new replacement is purchased such as what I had to do.

Instead, I used a self-tapping screw. This will both drill a hole and thread into the plastic. This screw is 3/4” in length. Try to keep the screw closer to the center so you don’t interfere with the fuel cap threads. Having a shorter screw won’t go through the base of the cap, so you should have any issues throwing a check engine light and having any plastic material fall into the fuel tank.

I did end up using this cap for quite a while before finally purchasing a new replacement.

And as you can see the cap can now be removed easily without any issues.

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