Hilux early chassis fail: rust perforation after 7 years and just 44k miles of road use in U.K.

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triggertrix said:
there's a trick to this. From early October just let the mud gather and create a barrier, wash it off again in the spring

:p
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I have a 2005 Seat Leon TDI FR that has 200k on the clock. I last washed the exterior in 2015. I have to clean the headlights periodically in winter when it gets to the point that I question whether they are actually working or not and always keep the brake lights clean. And I have been forced to clean the number plate a couple of times by plod when getting pulled over for not having a clear registration plate on display ha ha ha. One copper actually said to me "you have no number plate" I was like "I do, it's under there somewhere. He would not let me go until I had cleaned it.

Anyway, no rust on my car apart from the top of one of the rear wheel arches but internal arches are sound and the underside is amazingly solid considering the milage and how little care I take of it. Don't get me wrong, mechanically it wants for nothing and when it needs work, it gets it. I also give it new blood every 6000 miles like I always have done with all my cars irrelevant of what the manufacturer says. But apart from that, I just put derv in and drive it. Happy days.
 
zambezi said:
I bought a Hilux new in 2016 from my local U.K. dealer because of its acclaim on multiple continents by a range of users and media reviewers.

Since new, I have completed 44k miles [average of 6.4k p.a.] almost exclusively on tarmac in the U.K.

Out of the blue, the vehicle was declared to have failed its 4th MOT due to rust perforation of chassis within 40cm of a suspension point. The dealership and Toyota Customer relations are not interested in considering this to be a premature failure. CR make the point that the Toyota warranty is only for painted body sections. [see below]

I am disappointed in equal measure that (1) the failure could occur in so short time frame due to such benign usage (2) that the dealership that serviced the vehicle from new and who performed every MOT failed to flag the onset of rust at a point at which prevention could happen and (3) Toyota CR have no desire to make good.

If you buy a second hand Hilux, check the chassis. In particular, the OSR section.




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I was led to believe by SD members these Japanese pick ups were all “ bomb proof” build and reliability ( LR Disco 4 owner 137K miles no mot failures)
 
potshotpat said:
Jap Crap.
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TBH the old Hilux are still running about and we’re good value for money but the new ones at 50k + is an overrated price in my opinion . I’ve had a few Isuzu’s and found them great engines but sh..e chassis and repaired a few , 2.8t was the best then the 3.1 came along and it was sh..e , I’ve got a rodeo at the moment and buying another Isuzu soon as I think there good , not without fault but easy repaired and no bad rust so far . I had a Nissan Terrano for 5 years and all I done to it was put on a set of BF’s , estate model with the pongo leather seats , absolute Ant Hill Mob machine but it went anywhere in 4wd and I could get 7 Red in the back but the rust cancer got it , bought it for 900 and sold it 5 year later for 500 .. bargain 👍
 
Tim.243 said:
And there was little old me thinking that all these knowledgeable well read stalkers would have a man cave and welder..
Bit of Special K cardboard for a patten, decent shear trace the paten out cut it out. grind until clean and weld it up....

NOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOO :rofl:
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I spent long enough last year doing my disco 🤦 I'd be rather ****ed off if I had a new truck that was rotten though, atleast landrover you know it's happening 😂
 
Bugsy said:
old Hilux are still running about and were good value for money
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This Hilux replaced my old grey import Surf. As at the point I flogged it, the chassis on that 20 year old Toyota was still immaculate, despite spending more than half its life on British roads

Which is a paradox because it was built for Japanese roads and thus [according to received wisdom] did not have a chassis coating for our gritted roads.

By contrast, my 2016 Hilux was built by Toyota for the U.K. market. And the chassis failed in 7 winters????

Either Toyota now sell Hiluxs ill-prepped for U.K. roads, or Toyota QC has dropped off and this one was a dud. Either way, the absence of dealership flagging of incipient rust at each of the annual services from new is unforgivable.
 
zambezi said:
This Hilux replaced my old grey import Surf. As at the point I flogged it, the chassis on that 20 year old Toyota was still immaculate, despite spending more than half its life on British roads

Which is a paradox because it was built for Japanese roads and thus [according to received wisdom] did not have a chassis coating for our gritted roads.

By contrast, my 2016 Hilux was built by Toyota for the U.K. market. And the chassis failed in 7 winters????

Either Toyota now sell Hiluxs ill-prepped for U.K. roads, or Toyota QC has dropped off and this one was a dud. Either way, the absence of dealership flagging of incipient rust at each of the annual services from new is unforgivable.
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The reason I keep driving my 26 year old Gen3 Surf.
 

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Is it since they stopped using lead in the paint?

I often look at new trucks chassis's and usually they are rusting right away!

The accountants are running the show now in any corporate venture. Engineers are dumb!
I use to save all my old engine oil and fill the chassis inside and out regularly. Never failed mot 😊
 
Pickups for todays markets are like white goods … dispose of in 5 years because it ain’t worth repairing .. It’s like everything from pickups / cars / tools , even down to hunting trousers and jackets .You buy a pair of waterproof trousers for shooting and there the bollocks - comfy , good fit , plenty pockets , tough , good price , and after a hard couple of years you tell everybody how good they are and your buying another pair only to find out there superdooper succeeded by the maker but this time there double price , sh..e material , 2 pockets less , your balls are scrunched up and after 5 washes they’ve went from green to Sahara desert colour 🤷‍♂️.. it’s all about big money for something that ain’t going to last and falls apart on the washing line .
 
Bugsy said:
Pickups for todays markets are like white goods … dispose of in 5 years because it ain’t worth repairing .. It’s like everything from pickups / cars / tools , even down to hunting trousers and jackets .You buy a pair of waterproof trousers for shooting and there the bollocks - comfy , good fit , plenty pockets , tough , good price , and after a hard couple of years you tell everybody how good they are and your buying another pair only to find out there superdooper succeeded by the maker but this time there double price , sh..e material , 2 pockets less , your balls are scrunched up and after 5 washes they’ve went from green to Sahara desert colour 🤷‍♂️.. it’s all about big money for something that ain’t going to last and falls apart on the washing line .
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How big are your nads?
 
Bugsy said:
😂put it this way .. since I got the snip 12years ago there definitely a different shape - lie at a different angle and one is bigger than the other .. I asked the doctor did they run out of cable ties and had some jubilee clips left over ..
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My doc asked me if I had any kids, "no" say I "not surprising looking at those" says he.
 
Sealgair nam fiadh said:
I would still email Charlotte Dulake at Customer Support and inform her that her reply states " unpainted metal" and that your chassis was painted
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I did that today.

Shortly thereafter the dealership called. A long conversation ensued.

The service manager is good/solid. He had spoken to their MOT&service team re not flagging the rust sooner. The response was it was hard to know whether to worry a customer with news of some rust as its rate of development is unknowable.

The problem with that answer is that the suspension hanger limb was perforated front and back and the manager declared "it has corroded from the inside out".

That suggests poor chassis prep rather than external conditions I suggested. Anyhoop, he will now try to get an area QC adjudicator in to check the rest of the chassis...TBC.
 
Bugsy said:
😂put it this way .. since I got the snip 12years ago there definitely a different shape - lie at a different angle and one is bigger than the other .. I asked the doctor did they run out of cable ties and had some jubilee clips left over ..
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I had mine done....for months it was like having to pebbles in a leather bag!
Told the Mrs I'm not having that done again!!
 
zambezi said:
I did that today.

Shortly thereafter the dealership called. A long conversation ensued.

The service manager is good/solid. He had spoken to their MOT&service team re not flagging the rust sooner. The response was it was hard to know whether to worry a customer with news of some rust as its rate of development is unknowable.

The problem with that answer is that the suspension hanger limb was perforated front and back and the manager declared "it has corroded from the inside out".

That suggests poor chassis prep rather than external conditions I suggested. Anyhoop, he will now try to get an area QC adjudicator in to check the rest of the chassis...TBC.
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Get stuck into them and give them the “ Facebook threat “ in a nice way even tell them your father in law wants to put it on Farmers Weekly . It’s not right .
 
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