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  • Front Guard mount spot welds failing

    I was washing my Prado Yesterday (2004 GXL) and I noticed the extreme front of both guards was loose.
    The drivers side was very loose so I investigated today, turned out the spot weld on the bracket to the body that holds the front of the guard in place had failed on both sides. I haven't done very much off road in this vehicle only dirt roads and judging by the rust marks around the mounting point they have been broken for some time.
    I fixed them by removing the headlights for access and drilling out the spotweld and installing 6mm bolts with nyloc nuts to the brackets.
    Has anyone else had this sort of problem?? I have heard of cracking in the firewalls but this is a new one to me.

  • #2
    Re: Front Guard mount spot welds failing

    Any pics?
    [B][SIZE=4]ntp
    [/SIZE][/B][COLOR=#000040][B][SIZE=1]Love the Outback............. Love my Prado.[/SIZE][/B][/COLOR]
    [I][SIZE=1][URL="http://i520.photobucket.com/albums/w328/ntpryce/Picture23.png"]My Prado[/URL][/SIZE][/I], [I][SIZE=1][URL="http://i520.photobucket.com/albums/w328/ntpryce/MyExtras.png"]My Extras[/URL][/SIZE][/I]
    [B]4wdriving First Party[/B][COLOR=#0000ff] - [/COLOR][B][COLOR=#0000ff]dןǝɥ ɹoɟ ןןɐɔ 'sıɥʇ pɐǝɹ uɐɔ noʎ ɟı[/COLOR][/B]

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    • #3
      Re: Front Guard mount spot welds failing

      Lucky I took some photos,
      This shot is the drivers side with the headlight removed, you can see the surface rust behind the bracket as I have pulled it away a bit, so this is not a fresh break.


      This is the passenger side, you can see the film of rust running down the body so it has been like that for some time,
      The hole is a 6mm clearance hole for the bolt and nut to mount the bracket to the body.


      A bit of handy work with the screwdriver and spanner and its done,If you put a bit of Blutac on the ring spanner to hold the nut it will stop it falling out when you are trying to line it up.



      A liberal coat of soft seal to stop the rust before and after installing the bolts is a good idea.


      Job done, no more moving guards and shaking headlights. Looks a bit messy but I wiped off some of the excess rust preservitive later, no one can see under there anyway.
      amts
      Ninja Poster.
      Last edited by amts; 04-11-2017, 05:21 PM.

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      • #4
        Re: Front Guard mount spot welds failing

        In another lifetime (many years ago) i worked as a welder in a car factory, its hard to tell looking at the photos but i suspect it is a poor welding job. Basically a spot welder clamps an electode each side of the metal and pulses a current through to melt them together, the tips on the spot welding guns mushroom and the contact area get larger and larger, the operator should stop regularly and file the points to keep the contact area around 6mm, or replace them altogether when no more filing can be done. with the larger contact area the heat is less concentrated and therefore a weaker weld is achieved.
        Standard operating procedures mean that a cold chisel check should be done regularly in the factory, this involves trying to break the weld with a cold chisel. Maybe your Prado was built on a monday morning or a friday arvo :wink:
        I always prided myself on achieving an excellent product, the same can not be said for many that i worked with, even though we were building someones new car they just didn't give a S#%T! :evil:

        Cheers Andrew
        [COLOR="#FF0000"]So Long and Thanks for all the Fish![/COLOR]

        [url=http://www.4wdadventurers.com/showthread.php?3840-AJ-s-120-Prado]MY PRADO AND DIY CAMPER TRAILER[/url]

        [url=http://www.4wdadventurers.com/showthread.php?3975-AJ-s-79-series-Cruiser-Ute]MY HZJ79 Landcrusier[/url]


        [SIGPIC][/SIGPIC]

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        • #5
          Re: Front Guard mount spot welds failing

          Well spotted - and a good simple fix...
          2014 D4D 150 GXL Automatic - CHARCOAL

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          • #6
            Re: Front Guard mount spot welds failing

            Mine did the same about 2 years ago just did the same slamminsammy driiled spot welds out nut and bolted it.

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            • #7
              Suspicious Bracket Loose

              Hi team

              Hoping someone may know or have some info on this one...

              Was checking the truck for an upcoming trip and noticed a bracket under and near the front lights that does not seem to be welded or boltedto the side .. Is just seems to sit there and when you push the lights around you can see this move up and down slightly rubbing against the side...

              (this is a pic from the passenger side [i have marked the bracked with gold paint pen] - both driver & passenger seem same!)



              So, question is does anyone know if this is normal? Or has it become loose/free somehow?

              Cheers
              Borgy
              Prado VX Diesel 2007 Silver
              Lots of add-ons...
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              • #8
                i've read here before that someone noticed the lights were moving when going over pumps , and he found that the bracket behind the headlamp which was suposed to be welded is not anymore , and he secured the bracket by drilling a hole to be able to scure it with screw and nut , yet i'm not so sure if you have the same .
                [COLOR=blue]2006 VX ,5 Auto , currently Scan gauge II , Bonnet Guard ,wind deflectors,head lamp cover, dust deflector,insect net , Engel fridge,IPF fat boy,Hella FF300 lights,Toyota HD bars,BF 265/70 R17 A/T, Hella TPMS, K&N,OME 2",DBA , AirLift 1000 & Wirless Air control , ARB Comp,Safari Snorkel.[/COLOR]
                [URL="http://www.fuelly.com/driver/hisham/prado"][img]http://www.fuelly.com/smallsig-metric/52690.png[/img][/URL]

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                • #9
                  I can't quite workout where you have taken the pic from. I was under the car earlier today but didn't see this thread then.

                  If you use an allen key, can you locate a hole in the bracket?

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                  • #10
                    Hi..

                    I have the ARB BB and removed the under side wings protection plates and then looking up and behind the passenger side light this bracket is bolted at one end (nearest light) and the right angled down to the end where there is no hole or attachment point .. It just sits against the separate section of metal...

                    Not sure if it's a problem or if it do fix it will that create some other problem!

                    Cheers
                    Cheers
                    Prado VX Diesel 2007 Silver
                    Lots of add-ons...
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                    • #11
                      Originally posted by hisham saeed View Post
                      i've read here before that someone noticed the lights were moving when going over pumps , and he found that the bracket behind the headlamp which was suposed to be welded is not anymore , and he secured the bracket by drilling a hole to be able to scure it with screw and nut , yet i'm not so sure if you have the same .
                      Yep I concur. remember this thread where it was discribed as the spot weld coming apart. The solution was indeed as discribed above.
                      Cheers Troy
                      SOUTH AUSTRALIA GATEWAY TO THE OUTBACK!
                      2003 GXL V6 AUTO 120 CHAMPAGNE MICA [DUNE]
                      LIST OF ACCESSORIES GROWING, WISH LIST SLOWLY DECLINING

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                      • #12
                        found it

                        http://www.pradopoint.com/showthread...ght=headlights
                        [COLOR=blue]2006 VX ,5 Auto , currently Scan gauge II , Bonnet Guard ,wind deflectors,head lamp cover, dust deflector,insect net , Engel fridge,IPF fat boy,Hella FF300 lights,Toyota HD bars,BF 265/70 R17 A/T, Hella TPMS, K&N,OME 2",DBA , AirLift 1000 & Wirless Air control , ARB Comp,Safari Snorkel.[/COLOR]
                        [URL="http://www.fuelly.com/driver/hisham/prado"][img]http://www.fuelly.com/smallsig-metric/52690.png[/img][/URL]

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                        • #13
                          Threads merged gents...
                          2014 D4D 150 GXL Automatic - CHARCOAL

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                          • #14
                            Thanks... I will try to get under truck again soon to see if I can confirm this is the same issue /bracket location (always hard with Pics)... Looks like the brackets may be slightly different to the 2004 120 (mines a 2007)...
                            Prado VX Diesel 2007 Silver
                            Lots of add-ons...
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                            • #15
                              Originally posted by borgy View Post
                              Thanks... I will try to get under truck again soon to see if I can confirm this is the same issue /bracket location (always hard with Pics)... Looks like the brackets may be slightly different to the 2004 120 (mines a 2007)...
                              Hi all,

                              Thanks for the info in this one... Got under again this weekend.... Yep seems same bracket on the 2007... As outlined after removing the lower side plates of the BB it made the fix easiest by also removing the front headlights... Then a drill in where the spot weld was supposed to be and then a nut and bot fitted and the issue is now sorted!

                              Cheers
                              Borgy
                              Prado VX Diesel 2007 Silver
                              Lots of add-ons...
                              [url=http://autos.groups.yahoo.com/group/aussieswag/join][img]http://autos.groups.yahoo.com/group/aussieswag/[/img][/url]
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