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  • Known D4D engine faults

    Hi all, my 2010 GX 150 blew a hole in #3 piston at around 130000km. The debris from the piston went down the exhaust and destroyed the Turbo. I have a very good mechanic. I forked out $15k for a complete rebuild. He found out through US freedom of information (not shown in Australian information) that Toyota knew the pistons are faulty and were up to revision 7 pistons. So my engine has those pistons with a correctly spaced head gasket. My Mechanic double checked what he ordered and discovered the Toyota recommended gasket was too thick, so my engine got completely rebuilt with a new Turbo and Injectors. A short time after this disaster, I was going up a hill when the gearbox put out a teeth grinding scream and ceased to function. I got a new gear box $2500.

    What had happened was there is a splined bearing that the tail shaft slides in and out of from the transfer case. Mine had fatigue cracks and had split apart enough that the splines didn't engage. For a 4wd, this bearing is a thin walled 50mm socket, way under engineered. Finally, just weeks ago, my alternator died on my way back to Vic from QLD. We were stuck in Wollongong for 3 nights waiting to get a new 130 amp OEX one fitted. Another $800. The dead alternator, I blew out with compressed air when I got home and a lot of dirt blew out of it. There is a hint here, if you go on alot of trips in dusty tracks, dirt can build up in them and jam the clutch pulley.

    Illawarra Toyota didn't bother calling me back after I had an online chat with a dude. I had to get Lubemobile out to fit the new alternator.

    So, if anyone hears their engine tick at idle, it means a piston has cracked. I have a hatred of Toyota Australia over what happened to me. If my story can help anyone then that will be a good thing!
    Dangerduck
    Lurker
    Last edited by Dangerduck; 12-12-2017, 07:56 AM.

  • #2
    Sorry to hear this, I have a 2011 GX with 98K on the clock, when you say the engine ticked at idle did it tick all the time at idle, or only when cold and do you think that the cracks on the spline might have been visible with a good clean, close inspection of the spline and a spray of crack identifying fluid (not sure of it's name, Dymark I think). Looks like it is going to be a big exercise at 120k for me, with Injector change-out and tappet check as per Anths recommendations and looks like a piston change out would be worth it at the same time. Then not long after that a water-pump, belts and tensioners brakes etc etc aaaarrrrggghh, might flog it and buy a Hyundai.

    Comment


    • #3
      Did you do injector feedback and check your sump pickup before your engine went?
      Pistons don't just go bang for no reason.

      Do you have a copy of this freedom of information act? I'm sure with this you could have taken the matter to a small claims court and won the costs back from Toyota.

      Comment


      • #4
        Hi again,
        I did call/email Toyota about this. My mechanic is ex Toyota so he knew what to look for. Yes, mine did tick all the time but I didn't take any notice. I heard it at idle when I got the car to my mechanic. The piston did blow while I was towing my camper trailer up to Bendigo. I lost power majorly, blew stacks of white smoke and barely had the power to go up hills. Next day we limped into Bendigo to a Kmart auto who plugged their computer in which said #3 was at low pressure. We assumed it was bad fuel. When my mechanic heard it running for the 1st time after this, he popped the bonnet, listened and said number 3 has failed. Before the GFC hit, Toyota knew these engines would fail, so when you went into the service dept with a problem, they'd just chuck a new faulty engine in. The GFC changed all this. Thats how we found out about the revision 7 pistons. When the engine was pulled down, I saw #3 piston. It had a 5 cent piece hole in the top and was cracked down the side. We then noticed metal shavings in the exhaust manifold. My mechanic tried to spin the Turbo and it wouldn't budge. Hence the total rebuild, there were bits of piston in the oil sump and two of the bearing shells had score marks on them. It was a catastrophic failure.

        As I trust my Mechanic, when I rocked up on the back of a tow truck, he came out of his shop with a crestfallen face, asked what now? So the gear box came out, bits of the broken bearing were through it, hence a rebuilt gearbox.

        I should make something clear. I use my Prado as a 4wd. Im no idiot screaming around the bush damaging tracks. Ive done the Holland track in it, I was a member of the Eastern Goldfeilds 4WD club for 5 years, we did cape Legrand, Head of the great Australian bight, and numerous trips with the club. This is why my alternator died. Kalgoorlie is semi arid desert, the dust is red, full of iron. My warning goes out to all D4D owners, please get them checked. I don't want anyone else have to shell out the $19k in repairs I have. I heard from Toyota some 6 months after I contacted them about the above. AS SOON AS YOU MAKE ANY MODS for 4wding, Toyota australia drop you like a hot potato. Fact. They say the Prado's weren't meant for 4wding, my contention with the *asterds is why do you market them like this then? They don't give a flying F.

        The cracked Transmission bearing is inside the transfer case, so you can't see it. Now all the faults are fixed in mine, I love my Prado because it is no longer Toyota Australia spec!

        Comment


        • #5
          Sounds to me like checks on injectors and carbon blocking the sump pickup were missed. Leading to piston failure. Or perhaps a tip off a glow plug which also happens from time to time.
          I don't see why the GFC is to blame in any case?!

          Again if you have this paperwork showing that they knew of the fault and revision 7 pistons you'd certainly have a very strong case in court.

          Comment


          • #6
            I think it was carbon build up on number 3 injector. If I had the money and half a chance, I would take Toyota on over this. Unfortunately, my spine is buggered and I've survived a stroke, I no longer can work, no doubt, brought on by this story!

            Comment


            • #7
              What condition was the sump oil pickup in? Sounds like it has all the normal characteristics of a failure caused by injectors being out of spec.

              Comment


              • #8
                I'd have to ask my mechanic mate, I was completely unaware of what the tick meant. The day the engine blew, I had put Costco diesel in for the first time.
                That was why we thought it was bad fuel. Your dead right about the Injector being out of spec! This is why Ive told my story. If what Ive told prevents some other person going through what I did, it can only be a good thing. At least now I have a tonne of knowledge about my Prado.

                Comment


                • #9
                  Glad I changed my injectors out at 106k. Sounds like injector failure/over fueling in number 3. It seems the piston failure is linked to injector failure and is more likely to occur during towing or with an engine that has been chipped.
                  2010 150 Glacier White GXL D4D Auto

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                  • #10
                    Good on you! I reckon you've saved a tonne of cash by doing this!

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                    • #11
                      It's the same with the current air bag problem....every vehicle is being refitted with faulty airbags and Toyota knows it.

                      DPF...........

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                      • #12
                        Originally posted by Two89w View Post
                        It's the same with the current air bag problem....every vehicle is being refitted with faulty airbags and Toyota knows it.

                        DPF...........
                        Bold comment. Got any links or papers showing this ?

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                        • #13
                          Hi Piggy,

                          Could you send me a PM please.

                          Cheers
                          Geoff

                          Comment


                          • #14
                            Having replaced my injectors at 118000 as a precaution with no knocking I still had a piston crack at 139000. I had my new injectors tested (nothing wrong with them and the feedback values are still all less than 1.0) . I have researched another two engine failures - both 130000kms and the piston batch is the same as mine 040. The Toyota TSB is revised and states 080 as the old pistons needing to be replaced. I think you can safely say that unless your pistons are stamped 110 it is not if but when! The 110 pistons all went in to 2014 engines only!

                            Comment


                            • #15
                              Hi Scruffy -very sorry to hear of your engine failure despite being proactive in replacing your injectors.

                              What year is your Prado and have you done much of your milage towing?
                              Do you know the history timeline for the use of the 040, 080 and 110 pistons?
                              Can we say that the 080 is an improvement on the 040's?
                              I believe I missed out on the 110's as mine is a 4th September 2013 build -but I am hoping they actually replaced them a little earlier than stated as mine is the first of the 'face lift' model.

                              Did you have any blockage on your oil sump pick up at the time of your failure?

                              David

                              Comment

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