Foxclan's 2003 GXL V6

[Gramps Advanced Member Find all posts View Profile Close Gramps]

Nice write up Troy. Wish I was as game as you.

You've reminded me that my handbrake needs adjusting.

[foxclan Avid PP Poster! Find all posts View Profile Close foxclan]

How long before the GTG are you going to be in Tasmania? Might have a job for you now.

Gee thanks Mate, I've got a few jobs to rubber stamp before the GTG myself. Lol.

[Playdoh96 Member Find all posts View Profile Close Playdoh96]

Now I can see why you had so much trouble. That looked very painful. Good job mate!!!

[foxclan Avid PP Poster! Find all posts View Profile Close foxclan]

Now I can see why you had so much trouble. That looked very painful. Good job mate!!!

Cheers Playdoh96, actually minimal knuckle skin was lost during this job for a change.

[foxclan Avid PP Poster! Find all posts View Profile Close foxclan]

Got a report at the 150km service that the lower control arm (LCA) bushes were showing some wear.
My own inspection and less than ideal handling confirmed this.
So the research and sourcing of components began.
This was done in conjunction with the rack bush replacement above.
So with wheels and brake rotors removed. Sway bar dropped out also.
Calipers supported, ABS wire unplugged and carefully removed to prevent any damage to the fragile cable.
The front strut needs to be taken out to allow for LCA removal.
Follow these steps for strut removal.http://www.pradopoint.com/showthread...ade-for-Grande Thanks AMTS.
Once the strut was out the next task was separating the UCA ball joints. Remove the split pin from the crown nut, unscrew the nut until flush with the end of ball joint thread. Squarely strike the nut to release it from its tapered fit within the steering knuckle.
Support the steering knuckle, hub and CV shaft with a strap from the strut tower and an axle stand positioned underneath.
The UCA mounting bolt runs through the strut tower and both bushes, therefore its whole length is pushed forward for removal.
Depending on battery set ups the vehicle has it may be easier to remove both batteries for clearance and access.
No pictures of the UCA bush removal as this is where things got dirty! The OEM bushes are pressed in from the outside and naturally there is a oversized washer that will not allow for any press collar that I have to slip over.
My method was to cut the collar of with a ultra thin disc on the 5" angle grinder.
I then proceeded to drill out the bush rubber until the center tube could be removed.
Then the UCA goes in the vice to be cut with the hacksaw. Remove the blade from the hacksaw frame put it through the bush and reattach the frame.
As carefully as possible cut through the outer shell of the bush stopping before the UCA material.
I made two cuts in the bush, the first on the inner side of the UCA-opposite the ball joint.
This side has a hole in the UCA about 10mm in diameter.
Then at 180 deg. to the first
With a quality pin punch I was able to split the bush shell through this hole along my hacksaw cut line.
Then I worked my way around the shell until it was released and removed.
Cleaning up of the UCA with file, emery and linisher to smooth out any burrs or defects before the new bushes are installed is very important.
New Nolathane bushes being pressed into UCA.
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It takes time to find/make the right sized pressing shells, something that would be quicker if one had a lathe in ones workshop!

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UCA ball joints removed.
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I sourced ball joints for the upper and lower control arms from Bursons Auto they are Road Safe brand.

[foxclan Avid PP Poster! Find all posts View Profile Close foxclan]

While researching the control arm bush replacement job, I referred to Kevdebbi"s build up thread and also found that the FJCruiser forum had some useful info.
As we know the FJ and the 120 Series share some similar components and the Yanks love to modify their off roaders.
One such item of wisdom was that one should be prepared to cut out the LCA front adjuster bolt tube.
The tube gets seized due to corrosion within the bush tube.
Being made aware of this I contacted Toyota parts department before going any further.
Wow they actually had them in stock.
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With the LCA bolts removed it was soon clear that the front adjuster tube was solidly fused to the bush.
The FJ forum poster stated that he used a reciprocating saw to cut through the tubes.
Now a recipro. saw has been on my wish list for some time now, and I thought that this job was going to be the excuse I've been looking for to go and get one.
Well I grabbed the 5' angle grinder with a new ultra thin disc fitted, then was able to start cutting between the bush washer and the bush collar.
Pivoting the control arm to turn the tube around to allow for a complete cut.
Then by pushing the LCA inward in its adjustment slot of the chassis and pulling the rear bush outward the arm was free.
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These are the adjuster cams from bolt tubes and knurled washers, cut off as described above.
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This is the LCA front bush note the adjuster tube fused to the bush center.
post a picture One could say that rubber has seen better days.
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[foxclan Avid PP Poster! Find all posts View Profile Close foxclan]

I used the same method of OEM bush removal as for the UCA.
Prepared the LCA for the new bushes.
More pressing shells needed to be found to install the Nolathane bushes and replace the ball joints.
I then masked up the bushes and ball joints and gave the control arms a couple of coats of Dulux enamel.
Bushes all greased up and ready to go.

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While the struts are out and to continue with the theme, new lower bushes where installed.
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At last all the major bits back where they should be.
post a picture I centered the adjuster cams ready for alignment by Stable Suspension just up the road at Pooraka.
Road wheels back on lowered to ground for bolt tensioning.
Felt good on the way to the wheel alignment, felt even better after. Just had to take a run out of town to road test.
Bloody tough going at times for a DIY. The experience and the results have been worth it.
Keen to get it off road to feel how the Nolathane performs.

[mjrandom Out of control poster! Find all posts View Profile Close mjrandom]

Nice work.

[foxclan Avid PP Poster! Find all posts View Profile Close foxclan]

New rubber fitted 2/09/15

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Marveled at the ability of the BFG MT KM2 fitted to Playdoh96's vehicle back at the High country GTG, "No doubt driver ability played a large part also."

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Have found these tyres not to generate too much noise so far on road, but then only had her up to 80kmh.
I expect that they will pick up gravel on dirt roads, but looking forward to the low range stuff with them.
Cheers

[foxclan Avid PP Poster! Find all posts View Profile Close foxclan]

Another electrical accessory added today.

Had to trim the mounting opening slightly from underneath.

Araldite makes for a secure mounting.

Powered via ignition on cable. Also have Auxiliary battery powered Dual USB socket in rear of center console for kids equipment.

Cheers

[120D4D Avid PP Poster! Find all posts View Profile Close 120D4D]

Nice bit of disco blue mood lighting there Troy.

[foxclan Avid PP Poster! Find all posts View Profile Close foxclan]

Nice bit of disco blue mood lighting there Troy.

Barry White playing also...