hiluxxury wrote:Good luck. IMO you'll probably need an engineer to say it is a design flaw.
I had a very similar problem and went through the whole consumer affairs process to find that out. There are two problems here in Aus... 1. the state based consumers affairs bodies don't have the resources or the technical skills to make assessments and 2. the Aus market is very small so there isn't enough momentum for manufacturers to be afraid of forums etc - so they treat consumer law like toilet paper and put the onus on you to prove with engineers etc that the problem is theirs. In the US for example, the customer is right and manufacturers stand by their products.
Alternatively, you could fab a more forward sway bar mount based on what you have been supplied.
ironman have had a look & pull the camber I think he said, back 1º which has given the strut a 4-5mm gap. now the wheel rubs on the back at the bottom of the wheel arch. 265/70tyres 17rims.
they pulled me in to their work shop to show me that all things line up nothing looks wrong?? but the sway bar gap between the chassis & bar is maybe 4mm less then the driver side???
I have convinced toyota to have a look thanks to a fellow hilux driver that pulled up behind me as i was chatting. he had a rugged with a lift kit got the service tech to look at his. that led to him agree to look at mine.
now what happen on that day behind closed door who knows?
but like you said i may need to fab something or should i say ironman does!!!