I've surmised all along that (while not a reason to panic) all unreinforced (ield apron design) FJ's will EVENTUALLY get this problem. And 97% of the owners will never know unless there's a catastrophic failure. Chances are there won't be unless you're a hard wheelin', heavily modded rig kinda person who loves to bottom out!
It's a repetitive flex issue IMHO. The newest fender apron design has a bracket welded in. That is all. In fact, people getting the repair done now get the older apron design (2nd design w/ crush dimples located a little further apart) with the bracket that the body shop simply adds. The new part will have the bracket welded in during manufacturing.
I'm just P.O.'d that some body shop hacks are going to be snipping and welding sheet metal right up to the firewall...can you say accelerated RUST?!
Well, after Big Bear this last weekend I decided to check my fender aprons. I'm sorry to announce that my late-build (June 2007 with updated unner fender aprons) is bulging on the driver side. My setup is stock bumper without a winch, factory bling plate, TT factory suspension, with the updated (dimpled) inner fender apron. The only weight I added was the 2nd (high-pitched) horn
Clean area is where the bulge is:
Looking down on the bulge (it's a slight bulge, but it's there):
Passenger side is fine, so far:
So, I'm waiting for Larry to post the Toyota contact info (without reading thru the last 100+ pages....lazy, I know.... )
Mine are bigger than yours!
Very sorry to hear about a new body problem. Mine have not torn yet, but the left side is big...
I still think Demillo should work on this, and make a fix "kit" to sell people. New bolt-on fiberglass front panels? I would think a place that has the skill to make this could make a lot of money off it.
I don't know, but I am thinking that an aftermarket kit (even if it just "covers up" the flex problem) would be better than the fix Toyota has used thus far. Bet the price wouldn't be that far off from all the stock parts...
Well, after Big Bear this last weekend I decided to check my fender aprons. I'm sorry to announce that my late-build (June 2007 with updated unner fender aprons) is bulging on the driver side. My setup is stock bumper without a winch, factory bling plate, TT factory suspension, with the updated (dimpled) inner fender apron. The only weight I added was the 2nd (high-pitched) horn
This continues with my felling that the bulges are due to a front suspension / frame mount set up that is too soft - and allows too much flex and allows the wheel to bottom out into the inner fender well - both causing bulges. This is a separate issue from the rips, which are more likely, IMO, a resonant vibration issue that is not related to off-road use.
Contact Toyota corporate customer service to file a complaint and receive a case number. Then file a complaint with the NHTSA. Then go to your dealer and have them document the problem on a work order for your records and protection. Good luck
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Looks like I have a small bulge starting on my passenger side. It is pretty small and hard to see but if you put a straight edge on the fender it is easy to see. Is the inner fender supposed to be pretty much straight and flush to a straight edge if you don't have any bulges?
Looks like I have a small bulge starting on my passenger side. It is pretty small and hard to see but if you put a straight edge on the fender it is easy to see. Is the inner fender supposed to be pretty much straight and flush to a straight edge if you don't have any bulges?
that is the same as mine at this point. it is small on the passenger side, but still have it. i didn't put a straight edge on other FJs, but from the looks of it it should be flat.
Can someone tell me if there is a summary of what happens if you have bulges? Is there a conclusion to this somewhere? Thanks
The bulging & cracking are the same issue. Just like any sheet metal with repetitive flexing, it will eventually crack. You'll usually see small hairline cracks at first (often in the center of one of the crush zone dimples where the bulge is). In many cases, it stays that way and ceases or very slowly gets worse. In more extreme cases, it will flex until it cracks clean through. Check up under your wheel well. If you start getting more serious cracking, you'll see the undercoating breaking up and eventually see the crack(s) from under there.
I would imagine that eventually anything mounted forward of the cracks on the aprons will start flopping around (battery, fuse block, etc.), but I've never seen or heard of that yet.
I'm just a freak about RUST...and I've never seen a body shop return things to "factory" condition!
Location: "Sweet Talking Southern Gentleman" -Madame X
Posts: 2,698
Re: Engine Bay Body Rips
True dat.. Nothing is ever returned to "factory condition", especially body panels, paint, etc.. Ron
Quote:
MrTRD previously said:
I've never seen a body shop return things to "factory" condition!
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I just spoke with my local Toyota dealer - they are also a sponsor of my Land Cruiser club. The guy I spoke with had not heard of anything related to inner fender bulges. I'm going to try and get by this weekend for them to check it out. I'm nearing 33,000 miles and have to get this done before 36,000.
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/ WPOK492 
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