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Discussion Starter · #1 ·
My fJ has 13K and the driver door panel plasic has begun to crack on the armrest due to the weight of my elbow. ( probably due to my attempt at not trying to drag my butt over the weak seat fabric).
Toyotas going to replace it but says its only as a courtesy as they say no other door panel problems have been reported.
I really doubt that and feel the panel is weak and will probably fail again.
So sound off if youve noticed the same defect.
 

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No problemo with my door plastic. Two years also.
 

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? for ya, are you sayin youre putting weight on the panel while driving or when you are gettin in and out? cause if its in/out try the upper grab handle, its what I do n my seats look brand new (14000 miles) if its while your drivin then I really dont think youd have to worry about wearin on the fabric, cause youre not slidin around, unless you drive like a mad man
 

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My fJ has 13K and the driver door panel plasic has begun to crack on the armrest due to the weight of my elbow. ( probably due to my attempt at not trying to drag my butt over the weak seat fabric).
Toyotas going to replace it but says its only as a courtesy as they say no other door panel problems have been reported.
I really doubt that and feel the panel is weak and will probably fail again.
So sound off if youve noticed the same defect.

......Well in my time while I owned my FJ for 14 months and 33,000 miles.....I had my kids in and out of the back seats.....while almost 100% getting in through the drivers side.....that side of the seat had more wear with pulling of the fabrick was showing from the side they got in to less wear towards the passenger side......I forget what the mileage was at the time but.....it was only a few months into it (less than a year) and Toyota replaced the whole back seat cover....(lower section only)....and also said it was a one time courtesy.....STAND YOUR GAURD!!!.....for some problems with my FJ it took many calls and multiple months to finally get it taken care of......good luck
 

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15,000 miles and mine's broken too. Just like you said; (and it pinches the heck out of your elbow too)
Taking it in for routine maintenance next week - we'll see what they say.......
 

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Discussion Starter · #9 ·
Here we go again! I'm the original poster of this problem and at that time. Hamer Toyota replaced the panel after getting ok from the factory rep. That typical "this time only..courtesy..BS line". Since when should fixing their defects be considered a courtesy. Obviously to avoid admitting poor design. So after they ordered and then sent back the panel several times bevcause service and parts dept dont communicate. They finally replaced it on the fourth visit.
Now at 20K miles( 7k miles)..it's cracking again in the same spot. The plastic is only 20thousants thick at this point and if anyone presses thier thumb on the armrest youll see how it deflects. Plastic will fail just like metal with constant deflection. It's only a matter of time before more of these start failing..at least in my opinion. Im 6'2" so put the seat all the way back. That puts my elbow at the corner where it seems to crack. So perhaps more vertically challenged drivers havent had the problem yet ( just kidding).
Larry the dealer service manager advised that I drive with my arm on the window sill instead. My first Toyota and I'm not impressed with how Toyota stands in back of their products. They force you to jump thru hoops hoping youll give up and just go away.
Now I'll have to go thru the whole exercise again with no guarantee they will fix it.
Any advise?
 

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My guess is that the "squishiness" of the plastic is a "comfort" feature. That is, instead of using hard plastic there, they use this deformable plastic to comfort your elbow. However, cracking is a sign of poor quality. Does your FJ sit out in the sun a lot?? Do you have window tinting??

Can you buy a rubber/mouse fur/cushion/etc. or something to put over the plastic elbow rest?? This way, your elbow is happy and your armrest will lasts longer. Just a random google search for wrist rest: 3m Gel Filled Wrist Rest Grey WR310GY at TigerDirect.com

I have no idea if it will work but may be worth a try?? Or something similar to it.

Good luck.
 

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I just found a crack in mine at 28k miles and naturally 5 months after the warranty expired. I could tell from shortly after I got my FJ new that it would crack here. You can feel the plastic flex when you put any weight on it. I will see what my dealer says. I expect a problem with the vehicle being out of warranty. Has anyone had any luck repairing/reinforcing the cracked area? I was thinking about applying some sort of plastic repair material from the inside to prevent the crack from growing. Any suggestions would be helpful.
Thanks
 

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My fJ has 13K and the driver door panel plasic has begun to crack on the armrest due to the weight of my elbow. ( probably due to my attempt at not trying to drag my butt over the weak seat fabric).
Toyotas going to replace it but says its only as a courtesy as they say no other door panel problems have been reported.
I really doubt that and feel the panel is weak and will probably fail again.
So sound off if youve noticed the same defect.
Sam's here, I bought it with a cracked door panel, I tried super glue, tape, flex seal, and much more but can't fix it
 

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Mine has been cracked for probly 12 years or so. I took it to Toyota under warranty and they said they wouldn`t replace it. I repaired it once but I just recently noticed that the repair has failed. I`m going to figure out some kind of fix. :)
 

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Plastic weld from the back:
Harbor Freight plastic welding kit ($17.00)
weld/stitch it w/ the plastic stock, it also has metal mesh/screen for additional reinforcement,
(I'm thinking about filling it w/ gap-filler foam for additional support) (?)
D
 

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Basically its just a wood-burner/soldering iron body w/ a flat, triangular head;
my work don't look "purty" but you can't see it anyway! 😅
I've got a few extra of these foam floor mats
I'm thinking about cutting out a pad to glue to the top of the armrest as cushion
(& to keep from putting my elbow through it again... :oops:)
D
 

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Plastic weld from the back:
Harbor Freight plastic welding kit ($17.00)
weld/stitch it w/ the plastic stock, it also has metal mesh/screen for additional reinforcement,
(I'm thinking about filling it w/ gap-filler foam for additional support) (?)
D
That is a good Idea! You reminded me ,I actually have this stuff called Bondic (google it) that is a clear resin that repairs glass, plastic, almost anything . You apply it with pen then use a included blue light to cure it HARD it in about 5 seconds. It was created by a dentist and is the same stuff they use in dental procedures.
 

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Here we go again! I'm the original poster of this problem and at that time. Hamer Toyota replaced the panel after getting ok from the factory rep. That typical "this time only..courtesy..BS line". Since when should fixing their defects be considered a courtesy. Obviously to avoid admitting poor design. So after they ordered and then sent back the panel several times bevcause service and parts dept dont communicate. They finally replaced it on the fourth visit.
Now at 20K miles( 7k miles)..it's cracking again in the same spot. The plastic is only 20thousants thick at this point and if anyone presses thier thumb on the armrest youll see how it deflects. Plastic will fail just like metal with constant deflection. It's only a matter of time before more of these start failing..at least in my opinion. Im 6'2" so put the seat all the way back. That puts my elbow at the corner where it seems to crack. So perhaps more vertically challenged drivers havent had the problem yet ( just kidding).
Larry the dealer service manager advised that I drive with my arm on the window sill instead. My first Toyota and I'm not impressed with how Toyota stands in back of their products. They force you to jump thru hoops hoping youll give up and just go away.
Now I'll have to go thru the whole exercise again with no guarantee they will fix it.
Any advise?
I never rest my arm on that on that arm rest because of my height on the seat. I use the window sill, The cracking I have has to be from the outside of my knee hitting that spot right below the passenger window button (on the driver side door) It's from normal use . not flying off cliffs.
 
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