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Unread 08-15-2007, 10:01 AM   #1
Cruiserhead
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Default FJ Cruiser body cracks

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.p...98#post2447998
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Unread 08-29-2007, 03:16 PM   #2
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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??
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Unread 08-29-2007, 07:50 PM   #3
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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.
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Unread 08-29-2007, 08:07 PM   #4
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Interesting, maybe just a design flaw then. Hope Toyota gets it fixed then.
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Unread 10-19-2007, 03:45 PM   #5
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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.
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Unread 11-08-2007, 08:05 PM   #6
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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/forum...tml#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/forum...tml#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..."
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Unread 11-08-2007, 08:30 PM   #7
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Quote:
Originally Posted by SinCityFJC View Post
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-
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Unread 11-08-2007, 08:41 PM   #8
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Quote:
Originally Posted by Cruiserhead View Post
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.

I'm waiting to see how Toyota deals & fixes this issue, its becoming the final straw for me.
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Unread 12-03-2007, 11:18 AM   #9
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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!

[IMG][/IMG]

[IMG][/IMG]

[IMG][/IMG]
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Unread 12-03-2007, 03:15 PM   #10
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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.
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Unread 12-09-2007, 08:24 AM   #11
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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.
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Unread 03-05-2008, 02:14 PM   #12
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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.
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Unread 03-05-2008, 04:47 PM   #13
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I've been waiting since Oct 15th 2007 on what if anything Toyota will do for me.
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Unread 03-05-2008, 06:32 PM   #14
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As in buy it back?
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Unread 03-05-2008, 10:02 PM   #15
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Quote:
Originally Posted by mkaresh View Post
As in buy it back?
No buy back just waiting on a fix that works for bulges/cracks.
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Unread 03-06-2008, 12:04 PM   #16
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thankfully the bulges haven't appeared on our FJ yet ,then again it hasn't been jumped!
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Unread 03-06-2008, 01:29 PM   #17
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Quote:
Originally Posted by FJCcrawler View Post
thankfully the bulges haven't appeared on our FJ yet ,then again it hasn't been jumped!
No jumping of my FJ, bulges showed up right after a long road trip
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Unread 03-06-2008, 03:44 PM   #18
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did they find a way to fix it yet??? Or better yet, if they found a way to prevent it from happening again!
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Unread 03-06-2008, 03:54 PM   #19
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Quote:
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did they find a way to fix it yet??? Or better yet, if they found a way to prevent it from happening again!
No fix that works that I'm aware of. Some have had inner fenders replaced & got bulges/cracks again.
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Unread 03-06-2008, 06:10 PM   #20
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That's odd, how even when you replace the fender it still cracks!! do you have ANY idea of where the bulges and cracks might have came from???
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