Continue from where I left off,
The build to date hasn't been without issues. I guess it's time to share them as well.
I've have/had issues with the following:
Injectors
Clutch
Alternator
Tyre rubbing
Canopy
Electrical wiring
Rear diff
Dual Battery System
Injectors.
Those of you who have been following the injector threads will know of some of the hassle I had leading up to getting them replaced November last year. One Toyota dealership in Canberra went out of their way to be unhelpful and non committal, whilst another did the opposite. The first dealership started with the claim I didn't know what I was talking about, to being told by a service rep that the noise I could hear was my tyres, to being told that the injector noise was in fact my catalytic convertor (which they replaced). I gave up on them there and then and after advice from Matt (in Canberra) I went elsewhere, and was promptly told that the injectors were so bad they couldn't even test it at idle. It took another 2 months to get them replaced. I believe the rattle has returned, my engine is so noisy compared to most other hiluxs I hear around me, I'll be taking it back shortly for another look. Now that MMAAXX has posted the replacement requirements for the injector system; I'll be focusing on that as well. Thanks Max
Clutch
I had the thrust bearing replaced not long after I brought noodle, and have had it replaced 2 more times since then. The last time (Nov 09) they ended replacing the whole clutch unit including the fork. The bearing noise is back again, so I guess it will be off to the workshop for another look. If they will not play the game, I may look at getting the unit supplied by Brendon and the boys from Ultimate Suspensions, and taking the hit myself in the pocket. To be honest I have never really had any slipping issues, only had it overheat once on a fire trail, but the problem I have had was with shuddering on take-up. So this one is a watch and see issue
Alternator
I have this replaced once due to a bearing fault, and had it replaced with no problems at all, except for one clown at the dealership (the original one from the injectors) telling me that the winch and it electrical load that would have caused it to fail. He pulled his head in when I said that the winch was a Toyota accessory, and perhaps they should look at what they supply then. I have noticed whilst I have had the dual battery system, the battery monitor never goes below 13.5V when I'm driving, so the batteries are getting a good service I believe. I still use a 3 stage charger at home to give them a good condition charge though.
Tyres
Because I have fitted the old prado rims and 265/75/16 muddies, there have been the usual issues with rubbing. Because I have the Toyota Breaker bar on the front, there is more of an issue with the front edge of the tyres rubbing then there would be if I had an ARB or TJM bar. I have done some cutting work on the plastic, and now I only get an occasional rub when at 3/4 lock to the right... regardless of compression. I can live with that.
The ongoing problem I face with these old rims is the gap between the rim spokes and the brake caliper (see below)
I can fit a small metal rule in the gap between, and that is a snug fit, so only about 1-2 mm gap!!! I'm worried that the rim might flex one day and hit the caliper, but that would take a massive hit to do that, and the rim hitting the caliper would more than likely be the least of my concerns right then.
Canopy
As I said earlier, I purchased an Avenger canopy from Jesse and the guys early last year. I had the handle snap off in my hands when I first put in on the ute, but one call to Jesse, and I received a replacement within 2 days.... excellent service!
Over time, and constant rough driving (my 500m driveway seems like a fire trail some days) have seen a few issues raise their heads, but none that I wouldn't expect from any canopy given the conditions it's exposed to. The window rubbers are worn a bit, so the glass rattles around. I'll get hold of Jesse one day and see what he suggests. Because of the constant vibration from my driveway and the general road around here, the sealing rubbers glue gave up and I had to remove the canopy and reglue all the rubbers back on. Again, not something I would blame on this canopy, I think all canopies will do this eventually. The interior light doesn't work anymore, then on/off switch failed some time ago. Again I put this down to vibration. I was planning on replacing the light with an LED one anyway... another to do job. My only gripe about canopies with sealed front glass is you can't clean them easily.
Rear Diff
After my 80K service, I had a grinding noise and shuddering from the rear diff. Whenever I reversed into a parking spot the whole rear would almost leap off the ground and would shudder like mad. The noise was unbelievable. I called Toyota right away and was told that "my" diff had a really tight clutch pack in it, and because they replaced the oil, it would take a while to settle down again. Well after 200Km it was still there, so I took it in one day unannounced, and by the time I finished reversing into a parking spot in their service yard, I had 4 mechanics and the dealer principal standing outside to see what the noise was. They though a customer had come in and gone troppo on the cars hehe. Funny thing is they put it on the hoist, stood around scratching their heads form a while and then dropped it off the lift and gave it back to me. The service manager told me he wanted the ute for 2 weeks so they could remove the diff, dissemble the gears and get them checked out. Sounded at little worrying to me, but he said they could not find the cause, and wanted to strip it down to see. Organised the times and when I drove off, not a sound came out of the diff. Unfortunately for me the service manager quit a few days later, and when I dropped it off to get striped, they called me up to find out why they had it. Needless to say, unpleasant words were spoken..... and now 9 months later I have a whine in my diff on light throttle. Yet another thing to go back with.... the list is growing
Electrical
This one is bizarre and I have no idea how to find this, maybe you can help.
I fitted the gps unit from Digoptions, and fitted the rear camera as well. I wired up the camera power to the reversing light on the right rear light, and the reversing sensor for the gps unit comes from the relay behind the glove box, as described another post. The manual and wiring diagrams back this up........ The problem is this.....
When I am reversing (with no trailer on) and I touch the brake pedal, there is a period of time (1-2 sec) when the feed from the camera blanks out and then recovers the image. When I have a trailer attached, whenever I apply the brakes, the screen on the gps unit cuts over to the reversing camera window, but the camera does not come on...... I know this is pointing to a brake issue, but the system goes nowhere near the braking circuit. I initially put the problem in the rear light, but that would not explain why the camera screen comes on when I hit the brakes ONLY when a trailer is attached. The trailers are all LED, so the load is not that great, and I have the extra relay fitted by Toyota because of the lights in the bullbar.
Anyone got an opinion on this one? Beginning to do my head in this one is.
Dual Battery System
This one is more of a what should I do problem.
My current setup is a Piranha DBE180S+ feeding my starter battery and a Supercharge 105Ah deep cycle battery. I run all my accessories off the Aux battery, but nothing I have fitted is a big constant current draw item. The spotties are probably the biggest drain, but even that is only an occasional drain. All our fridges are in our camper trailer, which already has 220Ah battery system in it. I do connect this to the aux side of the battery system when we are on the road, but the batteries are always fully charged when we leave, and by the time we head home the fridge’s are either off, or turned right down so the drain isn't too high.
I also have the winch wired to the Aux battery which is a no-no I am Know, and that’s what is the root of my problem. I am pretty sure everything fitted to the ute can run off a normal battery, and keeping the winch on the deep cycle battery can only spell early death for it.... so I am thinking or removing the deep cycle and replacing it with a large capacity normal battery. If I do this, then I really don't need the dual battery system in the ute. If I run the 2 starting batteries in parallel, then the alternator can charge them up, and I'll continue to give them a monthly deep charge with the 3 stage charger like I do now.
I am thinking about removing the dual battery system from the starter batteries....... fitting a dc-dc charger, and using the Piranha system to switch this on and off. I would then use the dc-dc charger to run the batteries in the camper trailer. I would also add the old Aux battery to the camper, giving me a 300+Ah system.
What’s the general opinion on this?
That will do for now, there is more stuff to come, next is the future for noodle.