FJ Cruiser body cracks

[Cruiserhead]

This is something we discussed years ago on the Prado and it turned up on the FJC's now as well.
http://forum.ih8mud.com/showthread.php?p=2447998#post2447998

[bulldog]

Wonder why the FJC has that problem.

On the Prado it turned out that the fender cracked as folsk replaced the front body mounts wirth firmer units, to minimize body to bullbar movement on washbaord roads. THis casued the inner fender adn sometime firewall tocrack. Once they went back to the softer stock front bodymounts the issue went away it seemed.

Most of the guys with the cracks seem to be guys that run washboard roads pretty fast. Maybe some uprated bumpstops or softer front body mounts??

[daPitbull]

I don't have the full on cracked fender...yet, but I do have bulges (sp?) on both fenders; which seems to be how the cracks start. I haven't done any fast, washboard runs at all. The consensus on the blue forum is that the fender cracks are more prominent in the FJs with 06' build dates (like mine). Seems that the 07' builds have slightly different fenders. Toyota knows about this and they are investigating the problem. Most likely a TSB will be issued for this. I'm not too sure how they'll fix this without replacing the whole fender. This problem is effecting modified rigs and stock rigs.

[bulldog]

Interesting, maybe just a design flaw then. Hope Toyota gets it fixed then.

[SinCityFJC]

Started process with dealer on mine today, no visible rips but do have bulge on passenger side. Build date Jan 07, purchased Mar 07, 9500 miles, 95+% street.

[SinCityFJC]

My drivers side inner fender started bulging couple weeks ago or about a week after I took it into Findley about the passenger side bulging. Still waiting for any feedback or appointment for rep to look at it. Guess from Larry's 2nd post here good idea to wait for a real fix.

From CruiserLarry over on FJ Cruiser Forums

http://www.fjcruiserforums.com/forums/general-discussion/39106-attention-all-current-fjc-owners-5.html#post681343

"The repairs being performed currently involve replacing the inner fenderwells and core support. The engine stays, but all the electrical on the fenderwells is moved to allow for the repair, along with front bumper , radiator, A/C condenser, etc which are also removed.
I suggest people wait before allowing Toyota to perform these repairs, as it seems this repair DOES NOT cure the problem.

Field engineers usually have scheduled rounds at their area dealerships, so check with your dealer to find out when that rep is at their location."

http://www.fjcruiserforums.com/forums/problems-dealer-service/33440-engine-bay-body-rips-189.html#post678204

"Unfortunately, no. As I can now personally confirm that a repaired FJC has developed bulging AGAIN after hard off-roading (as was suggested to the owner by Toyota to test out the repairs), I am holding off on having any panels replaced. As I've personally hypothesized the entire time, I don't believe that replacing the inner fender wells alone will cure the problem - only address the obvious symptom. It seems I may be (sadly) correct. I feel (my opinion here - so tread lightly) that the fenderwell need to be braced by the outer fender skin, and the front body mounts should be firmer / shorter as well. All other Toyota trucks with similar suspension / build, such as the 4runner / Tacoma, have the inner fenderwell attached to the inner fenderwell at the top - making it more of a boxed design than the FJC's separate pieces. I think that would help stop the inner aprons from flexing as easily and bulging / cracking. We'll have to wait and see how Toyota responds to the second set of bulges on the same FJC - I guessing they'll realize that their work is NOT done..."

[Cruiserhead]

All other Toyota trucks with similar suspension / build, such as the 4runner / Tacoma, have the inner fenderwell attached to the inner fenderwell at the top - making it more of a boxed design than the FJC's separate pieces. I think that would help stop the inner aprons from flexing as easily and bulging / cracking.

That isn't accurate as the only other documented cases are from LC Prado 120's. The inner apron is constructed the same as the 4Runner and yet the Prado has the inner apron tearing issue.

I don't think the assumptions or theories are good to put out as root causes.
There could be factors unknown to non-Toyota engineers, or something not thought of at this point.

It is good to stick to the facts- frustrating maybe- but it's the only way to keep the history accurate-

[SinCityFJC]

That isn't accurate as the only other documented cases are from LC Prado 120's. The inner apron is constructed the same as the 4Runner and yet the Prado has the inner apron tearing issue.

I don't think the assumptions or theories are good to put out as root causes.
There could be factors unknown to non-Toyota engineers, or something not thought of at this point.

It is good to stick to the facts- frustrating maybe- but it's the only way to keep the history accurate-

Well if you just SAS it like Demello did & plate front frame rails I'm guessing that woud fix it.:bigok:

I'm waiting to see how Toyota deals & fixes this issue, its becoming the final straw for me.

[SinCityFJC]

I do have the bulges on mine & been waiting for Toyota to call & look at it, I'm not in any hurry since they don't appear to have a fix for it.

I do have another symptom that showed up that may be related - bracket that holds outer fender & fender flare broke its spot welds - I can now move outer drivers side fender up and down easily with one hand. Note this rig has not been jumped!

http://inlinethumb46.webshots.com/31277/2539085580050172860S500x500Q85.jpg (http://rides.webshots.com/photo/2539085580050172860DJQIAV)

http://inlinethumb40.webshots.com/31911/2730588630050172860S500x500Q85.jpg (http://rides.webshots.com/photo/2730588630050172860UvSpRM)

http://inlinethumb52.webshots.com/32499/2422815560050172860S500x500Q85.jpg (http://rides.webshots.com/photo/2422815560050172860hMTnzu)

[bulldog]

Hmm interesting. Seems like Toyota might be sending some units to the body shop. Only thing is they will need to redesign the fenders to make it stronger to avoid the problem for repeating.

[mkaresh]

None of these reported by participants in my research yet, but then I ask only about repairs, not about problems that haven't yet been repaired. Sounds like many people could still be waiting for a fix.

[mkaresh]

I've now had some people report these to me via email, but none have been repaired, so they're not reportable on the main survey.

[SinCityFJC]

I've been waiting since Oct 15th 2007 on what if anything Toyota will do for me.

[mkaresh]

As in buy it back?

[SinCityFJC]

As in buy it back?

No buy back just waiting on a fix that works for bulges/cracks.

[FJCcrawler]

thankfully the bulges haven't appeared on our FJ yet:bigok: ,then again it hasn't been jumped!;)

[SinCityFJC]

thankfully the bulges haven't appeared on our FJ yet:bigok: ,then again it hasn't been jumped!;)

No jumping of my FJ, bulges showed up right after a long road trip

[FJCcrawler]

did they find a way to fix it yet??? Or better yet, if they found a way to prevent it from happening again!:bigok:

[SinCityFJC]

did they find a way to fix it yet??? Or better yet, if they found a way to prevent it from happening again!:bigok:

No fix that works that I'm aware of. Some have had inner fenders replaced & got bulges/cracks again.

[FJCcrawler]

That's odd, how even when you replace the fender it still cracks!!:eek: do you have ANY idea of where the bulges and cracks might have came from???:confused: :confused:

[SinCityFJC]

That's odd, how even when you replace the fender it still cracks!!:eek: do you have ANY idea of where the bulges and cracks might have came from???:confused: :confused:

A lot of speculation but Toyota is being quite on the issue, I imagine till they come up with a solution.

[FJCcrawler]

So, how long has it been since you told toyota about this issue???;)

[SinCityFJC]

So, how long has it been since you told toyota about this issue???;)

Oct 15th or almost 5 months. I'll be out of warranty in just over a year & I don't see myself keeping the FJ past then.

[FJCcrawler]

Oct 15th or almost 5 months. I'll be out of warranty in just over a year & I don't see myself keeping the FJ past then.

They'll probably get things sorted out within a year if not less, but if you're not going to keep the FJ what are you going to get????? a 4runner :confused:

[DominicG]

These cracks/bulges are so random. I've seen a bulged and cracked 2x4 that had never left the asphault. Compared to mine, no bulges or cracks! And I do a lot of slow going stressful crawling, and fast desert running where i usually get a lot of nose dives and tire stuff. It's just a strange problem...

[SinCityFJC]

Well Toyota Corporate is Not going to back their product or honor the warranty on my FJ Cruiser - excuse is that it's lifted & it's a user issue not a product/design problem. Good luck with your FJ's I'm outta here & hell will freeze over before I buy another Toyota product.

My web page dedicated to the FJ Cruiser that I'm just starting. http://rides.webshots.com/album/569086712jgHQHb

Plus YouTube Video from yesterday. http://www.youtube.com/watch?v=QIHk8zrjiNo

[expat]

So are you selling it?

[SinCityFJC]

So are you selling it?

Yes will be - needs a new home.

[mkaresh]

Good customer care isn't guaranteed with any manufacturer. The main reason that Toyota has taken so many customers from Detroit is that there have been fewer problems, not because Toyota handled the problems that did occur better.

[SinCityFJC]

Good customer care isn't guaranteed with any manufacturer. The main reason that Toyota has taken so many customers from Detroit is that there have been fewer problems, not because Toyota handled the problems that did occur better.

Hey at least my experience with the big 3 (use to manage Co. Fleet) is if they are going to screw you there prompt about it. Toyota appears to prefer the delay method & I'm not that patient. Also if I knew this was the outcome I would of sold the FJ before the front clip got so bad & the economy took a dump.

[expat]

So what will you be replacing it with?

[SinCityFJC]

So what will you be replacing it with?

Most likely a Jeep - :tequila:

Don't want another IFS rig so options are limited.

[4mudder]

Most likely a Jeep - :tequila:


I see you're crossing to the dark side...:devil: Sorry to hear about your body issues but I personally think Chrysler products are the worst way to go.:2cents

[SinCityFJC]

I see you're crossing to the dark side...:devil: Sorry to hear about your body issues but I personally think Chrysler products are the worst way to go.:2cents

Just going back from were I came - :devil:

Yes Chrysler has lots of issues but the FJ is the only one that left me stranded on the trail.

My FJC @ 24k miles has other issues besides front end self destructing - but not going to bother taking it in for recurring christmas dash, intermittent sluggish/strange shifting trans, T case shifter rattle, intermittent rough idle ect.

In hind sight my last 3 Jeeps had less issues and the ones they didn't warrantee were easy fixes - a FJ's structural design flaw I cant fix with out taking a plasma cutter to it/ reinforcing the front section of the frame & installing a SAS.

If you hadn't guessed I think the fender bulges/cracks & weld failures are only a symptom of a larger problem.

[4mudder]

Wow....
I think you just got a lemon. That's rare for Toyota but it still happens. Sorry to see you leave the family. Good luck with your Jeep and we'll see you on the trail.:drink:

[SinCityFJC]

Wow....
I think you just got a lemon. That's rare for Toyota but it still happens. Sorry to see you leave the family. Good luck with your Jeep and we'll see you on the trail.:drink:

Did meet some great people & lots of great trails while in the Toyota family.

See you on the trails :cheers:

[expat]

Oh bummer! You were an asset to the Toyota 4x4 community. A solid axle Jeep can be damn sweet tho.

[SinCityFJC]

Oh bummer! You were an asset to the Toyota 4x4 community. A solid axle Jeep can be damn sweet tho.

Especially when you do this with long arms/travel & coilovers F&R

http://www.youtube.com/watch?v=plvw4Qk9vys

It was hard for me to keep up with him in my FJ's strong suit high speed baja style & sand.

[expat]

Nice! Although I'd not want to commute in that, nor be driving in cold weather, rain, dust etc and I reckon Joels Runner would kill that in a baja run. Stability at high speed could not be its strength. All the same, a very cool crawler.

[SinCityFJC]

Nice! Although I'd not want to commute in that, nor be driving in cold weather, rain, dust etc and I reckon Joels Runner would kill that in a baja run. Stability at high speed could not be its strength. All the same, a very cool crawler.

He and others stretch the wheel base to 100-104" plus with less backspacing on rims giving a wider track makes them a hell lot more fun & safe off camber & at high speed.

[mkaresh]

Especially when you do this with long arms/travel & coilovers F&R

http://www.youtube.com/watch?v=plvw4Qk9vys

It was hard for me to keep up with him in my FJ's strong suit high speed baja style & sand.

Damn, got enough suspension travel and ground clearance?

[SinCityFJC]

Update on mine - total BS on all counts - denied coverage on all issues.

Click on pic will take you to full size version.
http://inlinethumb18.webshots.com/40785/2697291700050172860S600x600Q85.jpg (http://rides.webshots.com/photo/2697291700050172860fGDSmU)

ps: Big thanks to Tigger my FJ Cruiser will be wearing some custom decals.

[4mudder]

That's crap!!

I am looking at a shiny glossy brochure that Toyota sent me for being a loyal 4Runner owner, and guess what??? In the SUV/VAN section is a picture of a 2009 FJ Cruiser traversing a big ass rock. If you look at the pic you can see it's lifted, on 33's or 35's with aftermarket wheels and tires and sporting a winch bumper. So the excuse of "...it's been modified, it's not covered" is a load of BS. (read the photo caption in pic #2)

http://i534.photobucket.com/albums/ee349/cbrezman/Offroading025.jpg

http://i534.photobucket.com/albums/ee349/cbrezman/Offroading026.jpg

BTW, this is exactly why I never bought my Jeep from Chrysler all those years ago. The dealer also had a glossy brochure showing a Wrangler on top of some butte in Utah, you know "offroad" and the super fine mice type at the bottom said... "Vehicle warranty is void if vehicle is ever taken off-road..." Considering that all the advertising for the Wrangler was centered on its off-road prowess (just like the FJ Cruiser) I thought this was really disingenious on the part of Chrysler and walked away.
:2cents

[SinCityFJC]

Since some are asking:

I have no issue with Findlay Toyota - Robert & Brett are great to wheel & deal with. In the big picture I only have a minor issue with Desert Toyota.

I know it's not the dealers decision on my issues with my FJ Cruiser, its Toyota Corporate.

The FJ Cruiser is a tragic mess right now for Toyota & effected owners. I should of instead bought a Tacoma, 4 Runner or waited a few years

[my034runner]

Since some are asking:

I have no issue with Findlay Toyota - Robert & Brett are great to wheel & deal with. In the big picture I only have a minor issue with Desert Toyota.

I know it's not the dealers decision on my issues with my FJ Cruiser, its Toyota Corporate.

The FJ Cruiser is a tragic mess right now for Toyota & effected owners. I should of instead bought a Tacoma, 4 Runner or waited a few years



Well, then let me put you in a Tacoma or a 4Runner then!!! :cool1: The new 2009 Tacoma's are Bad Ass!!! Locker, A-Trac, VSC, DAC, HAC, bitchin kick ass stereo, etc... :rockon:

BTW, Thursday, we had the launch for the new Venza @ Mandalay Bay...what a bitchin car!!!!

But, this isn't about the car.

Our Toyota Denver Region Tech rep. (forgot the actual title) his name is also Brian.
He's actually a cool ass dude, and wheels too..he has a bad ass 80, and has actually been out with us before.
I explained your situation, and the facts as I know them. Also showed him this thread, and he forwarded it to some higher ups. I'm trying to get some help from someone, and hope he can get something done for you.

He explained about how Toyota has inspected all of the Trail Teams FJC's for any of the same issues, and haven't found any.

Also explained your level of expertise as far as your driving skills, and the fact that your FJC has Never been jumped nor bottomed out before.

I told him that's BS, and that they are going to drive good customers away from what, I still consider the best brand in the world. I hope he can have some positive effect and outcome for you Brian. And gave him your phone #, in case he needs to get a hold of you.

[SinCityFJC]

Well, then let me put you in a Tacoma or a 4Runner then!!! :cool1: The new 2009 Tacoma's are Bad Ass!!! Locker, A-Trac, VSC, DAC, HAC, bitchin kick ass stereo, etc... :rockon:

BTW, Thursday, we had the launch for the new Venza @ Mandalay Bay...what a bitchin car!!!!

But, this isn't about the car.

Our Toyota Denver Region Tech rep. (forgot the actual title) his name is also Brian.
He's actually a cool ass dude, and wheels too..he has a bad ass 80, and has actually been out with us before.
I explained your situation, and the facts as I know them. Also showed him this thread, and he forwarded it to some higher ups. I'm trying to get some help from someone, and hope he can get something done for you.

He explained about how Toyota has inspected all of the Trail Teams FJC's for any of the same issues, and haven't found any.

Also explained your level of expertise as far as your driving skills, and the fact that your FJC has Never been jumped nor bottomed out before.

I told him that's BS, and that they are going to drive good customers away from what, I still consider the best brand in the world. I hope he can have some positive effect and outcome for you Brian. And gave him your phone #, in case he needs to get a hold of you.

A big thanks Robert - 100s if not 1000+ people have been wheeling with me over the years - I do from scenic to technically challenging trails but not out there trying wheel till I break ****.

There are some shots of my FJC out there & in print that look more extreme than they were & hate to admit it were promotional shots for HnB sponsors & magazines. :tequila:

[4mudder]

Our Toyota Denver Region Tech rep. (forgot the actual title) his name is also Brian.
He's actually a cool ass dude, and wheels too..he has a bad ass 80, and has actually been out with us before.
I explained your situation, and the facts as I know them. Also showed him this thread, and he forwarded it to some higher ups. I'm trying to get some help from someone, and hope he can get something done for you.

I told him that's BS, and that they are going to drive good customers away from what, I still consider the best brand in the world. I hope he can have some positive effect and outcome for you Brian. And gave him your phone #, in case he needs to get a hold of you.

I'm really glad this is finally getting the attention it deserves! Good luck with the outcome Brian.

[SinCityFJC]

I'm really glad this is finally getting the attention it deserves! Good luck with the outcome Brian.

Decals for F&R windows & hood arrived last Saturday. Might remove if they fix mine & issue a TSB for these design/product issues

http://inlinethumb21.webshots.com/39316/2730617990050172860S600x600Q85.jpg (http://rides.webshots.com/photo/2730617990050172860qspHbS)

Were pics of TT rigs with bulges/cracks on the net. Also - sorry Robert your being lied to. Also had this reply e-mailed to me from someone in the know:

"want to know something, they are no longer allowed to open the engine bay of a FJC that is owned by Trail Teams with the public around. They actually told me they were sealed."

[expat]

Funny sticker...LOL

Not so funny situation...Grrr

[SinCityFJC]

Making fun of a bad situation Jeepers & FJ owners are sending me suggestions for additional decals:

"honk if any parts fall off"

"Keep Back 500 Feet, My Front End Could Fall Off Any Minute"

"Feel my fender bulges" - cleaned up version :rotflmao:

"Feel my Bulges & Check Out my Cracks"

[SinCityFJC]

Blog with videos dedicated to Floppy - http://worst4x4xfar.blogspot.com/

[07 Elephant]

What a mess. Truely sorry.

[SinCityFJC]

What a mess. Truely sorry.

Thanks & yeah it sucks when your Toyota turns into a beater in less than 2 years