Replace chassis on 90 Series GXL. Help!

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Hi everyone I bought my GXL about 18 months ago and love it. When I took it in the for a RWC for rego renewal my mechanic called me in to show me that the chassis was very badly rusted out and someone had bogged it up to disguise the problem. I have tried to find someone to replace it for me but nobody wants to do it. I am now in the position of having to do it myself.

Has anyone of you done this before and can please give me some advice and pointers?? I have no choice but to fix it because I'm between a rock and a hard place, I can't sell it, I can't trade it in and I still owe $12k on the car loan. My only option is to fix it and keep the vehicle to get my value out of it. Apart from the chassis problem it is in great condition. I've been to Fair Trading and the MTA but have been told I have no come back on the car yard .

Any help and advice would be greatly appreciated. Thanks, Paul

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

Have you got some photos Paul of the effected area, I haven't heard of any 90s having rusted chassis before.

Doesn't sound good mate.

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Hi Richard, I'll take some pics and post them. But it's pretty bad. I have had a panel beater take a look and he said it's too bad to cut a bit out and replace. The worst bit is toward the back were the diff support is but it is right through most of the chassis. The panel beater reckons it looks like the previous owner had been putting a boat in and out of the water at the beach.

[Roktruk Junior Member Find all posts View Profile Close Roktruk]

I'd keep pushing the MTA/fair trading line. If it's as bad as you say, then the car yard would have some liability in selling a vehicle with an inherent fault.

Do you have the service books? You might be able to track down the previous owner and find out it's history. Check thoroughly under the carpets and inside doors etc for sand as it may have even gone for a swim at the beach.

I remember watching an Esperence (WA) fisherman launch his boat - backed the 60 series doen the ramp until the boat floated off the trailer, which meant the 'cruiser had water 1/2 way up the rear doors! His attitude was "I'll trade it on a new one next year...."

I bought my 60 from a wheatbelt town.....

[carrot Junior Member Find all posts View Profile Close carrot]

I've never done a chassis swap, it sounds like a really big job! I'd probably get a badly rolled or burnt prado at the auctions. And find someone that knows what they are doing to help!

[big al Junior Member Find all posts View Profile Close big al]

Replace shasis on 90 series GLX.

Hi Paul.Going to be a very big job and will take some time to complete,but very doable.You are going to require something more substantial than the gregorys manual to get you through this.You will need a complete factory workshop manual. Follow it to the letter.A good tip here is to lable wires and thing that arnt obvious,on each end with masking tape,you can write a code on the tape like A joins A, B joins B and so on.Also ink whiteout is helpfull on hoses and things alike, one dot on this hose and one dot where it come from,two dots on the next and two dots where it came from and so on .This will help when you go to reassemble things.Id be looking to remove the cab first,this will make the running gear change over easier.Good luck Paul.PS will watch this forum for your progress and if need advise refer to this forum as I have found the members here to be very helpful and imfomative.

[big al Junior Member Find all posts View Profile Close big al]

Avoid burnout.

Paul. It would be wise to avoid a replacement chasis from a burnt out vehicle.The extreme heat would have affected the metal and possibly caused some warping,it will also be prone to rust very easily and you are back where you started.By for now.Al.. :idea:

[BAZPRADO Senior Member Find all posts View Profile Close BAZPRADO]

Never heard of this project for a Prado, although it was common on the old Range Rovers! Your best bet is to sell it as parts, you may get more than what you owe if you play it right Best of luck to you.

[big al Junior Member Find all posts View Profile Close big al]

Rusty chasis

Hi Baz&Paul, Been under my 4x4 a lot lately.The prados have a full chasis much like the old HQ Holdens had and it looks like the body lifts away from the chasis in the same manner as the HQs.There does not appear to be a lot of mounting points. by for now. Al... :idea:

[Mick Lurker Find all posts View Profile Close Mick]

Hi mate

'BIP Toyota' in Melbourne have been the best I have found as far as wrecking prado's goes. Not many do them.
Either ask him what he'll give you for yours as is, or alternatively ask him if he has a decent chassis for you
Hope this helps and all the best

PM me if you want the details for BIP

Mick