Is the 150 showing any signs of cracked inner guards

[AJ120 Out of control poster! Find all posts View Profile Close AJ120]

Just a little story you might like to hear before you go beefing up the gaurds.

Many years a go when I worked as a welder in a car factory; one of the workers ordered a new car and he got the build number pre production and went along the production line; following his car and getting all the welders to put lots of extra welds on everything in order to make it much stronger.

Long story short, the car was a pig to drive and started to rattle and crack within a couple of years, and this was a town car not a 4wd. Cars are meant to flex a bit and making them stronger isn't nescessarily the best answer, you might just create another problem, or shift the stresses to another point due to a lack of flex.

Something to consider before spending money fixing a problem that hasn't occured yet!

Cheers Andrew

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

If you're going to reinforce the guards you really need to be careful that you don't create new stress points for cracking.

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

If you're going to reinforce the guards you really need to be careful that you don't create new stress points for cracking.

So what's the answer?


Steve.

[AJ120 Out of control poster! Find all posts View Profile Close AJ120]

So what's the answer?


Steve.

If it aint broke don't fix it!

Cheers Andrew

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

If it aint broke don't fix it!

Cheers Andrew

And for those who have a broken one? If welding the crack does not fix it and it keeps coming back?

I don't mind if it breaks if there is a fix, but for those who have had it crack, what's the solution?


Steve.

[Geoffury Find all posts View Profile Close Geoffury]

One technique a sheet metal worker showed me on my old Hilux which had a crack on the inner guard, was he drilled a hole, 1/4 " at the end of the crack, and then welded the rest of the crack up. Once it cooled, painted it all in rust proof.

He said if we just simply weld it all, it will continue to crack over time. He was right in my instance. Never cracked again.

Not saying it will work in ever case, but the crack on the lux was about 100mm long, and I could get my finger nail in it.

[AJ120 Out of control poster! Find all posts View Profile Close AJ120]

One technique a sheet metal worker showed me on my old Hilux which had a crack on the inner guard, was he drilled a hole, 1/4 " at the end of the crack, and then welded the rest of the crack up. Once it cooled, painted it all in rust proof.

He said if we just simply weld it all, it will continue to crack over time. He was right in my instance. Never cracked again.

Not saying it will work in ever case, but the crack on the lux was about 100mm long, and I could get my finger nail in it.

That is not only true for sheet metal, we do that with cracks in earthmoving machinery which may be upto 20mm thick steel in some instances. Definately the correct way to repair it.

Cheers Andrew

[Hutch Addicted PP Member Find all posts View Profile Close Hutch]

Makes sense same as a crack in the windscreen we use to drill at the end of the crack and then fill with resin.


Hutch- 2012 Prado 150, some TJM Kit.

[outback7 Banned Find all posts View Profile Close outback7]

Hey Wooley, I talked to Roo about that he said no.....different shape guard. Roo is trying to source one for the 150.

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

One technique a sheet metal worker showed me on my old Hilux which had a crack on the inner guard, was he drilled a hole, 1/4 " at the end of the crack, and then welded the rest of the crack up. Once it cooled, painted it all in rust proof.

He said if we just simply weld it all, it will continue to crack over time. He was right in my instance. Never cracked again.

Not saying it will work in ever case, but the crack on the lux was about 100mm long, and I could get my finger nail in it.

Drilling a hole reduces the stress concentration. Have to be careful welding as that can introduce new stress.

[Schniff Member Find all posts View Profile Close Schniff]

It definitely is an expensive fix, to ensure it doesnt come back the skirt needs to be cut out and a new one welded in. Everthing on that side of the engine bay has to be taken out, including the main wiring loom that goes through the firewall if fixing the passenger side. You are looking at $3-4000 per side. Make no mistake this is a serious issue and I would no longer recommend the Prado for serious outback travel.

I paid $900 to get my cracks welded and it was definitely not the right way to fix it. They cracked on the very next trip far worse than before. Once they start to go, they generally don't stop if subjected to the same stresses.

[rob_macca67 Avid PP Poster! Find all posts View Profile Close rob_macca67]

Posted this in another post.... thought I'd better post it here as well........

I've just heard back from Toyota Australia in regards to the Inner Guard Crack.... as expected they deny any responsibility and pushed the blame onto ARB. I've contacted ARB and they have been VERY helpful, so hopefuly we can get Toyota to reverse their decision, especially when they put the blame on as quoted "The cracking has occurred because the front cab mount has been modified when the bullbar was fitted. The squash tube of the front body mount was replaced which made this mount much stiffer. This introduced stress into the front guards eventually causing cracking" They went on to say this isn't the 1st instance they have seen this with that particular bullbar manufacturer.... What a load of BS !!!

I can feel the grey hairs coming now.....

[AJ120 Out of control poster! Find all posts View Profile Close AJ120]

I've just heard back from Toyota Australia in regards to the Inner Guard Crack.... as expected they deny any responsibility and pushed the blame onto ARB. I've contacted ARB and they have been VERY helpful

Does this mean that ARB has accepted some of the responsibility and are willing to chip in for some of the repairs?

Cheers Andrew

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

The cracking has occurred because the front cab mount has been modified when the bullbar was fitted. The squash tube of the front body mount was replaced which made this mount much stiffer

What is the squash tube and was it actually replaced?

[rob_macca67 Avid PP Poster! Find all posts View Profile Close rob_macca67]

Does this mean that ARB has accepted some of the responsibility and are willing to chip in for some of the repairs?

Cheers Andrew

No, but they're going to look into it (I hope). The main person involved is on A/L and back next week, so I'll know more when I speak to him.... I don't know the what outcome will be but if they can help me disprove what Toyota has implied and get them to reverse their decision, I'll be a happy man...... it might be a LONG shot, but better than nothing.... otherwise it's an insurance repair & I wait another 2yrs or so when the lease is up & get rid of it & will never buy another new Prado again..... back to an older/stronger model 4WD for what I want to do....might look at the last of the 100's TD....

In the meantime I'll have to squeeze the family into my D22 DualCab for any remote touring that involves corrugated roads, etc.... what a shame Toyota