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If you are experiencing body rips or bulges with your FJ, what setup are you running?

  • Stock bumper, no lift

    Votes: 147 28.9%
  • Stock bumper, w/lift

    Votes: 51 10.0%
  • Stock bumper, w/lift and 285/70 17's

    Votes: 51 10.0%
  • ARB bumper, no lift

    Votes: 6 1.2%
  • ARB bumper, with lift

    Votes: 22 4.3%
  • ARB bumper, w/lift and 285/70 17's

    Votes: 44 8.6%
  • WARN bumper, no lift

    Votes: 7 1.4%
  • WARN bumper, w/lift

    Votes: 14 2.8%
  • WARN bumper w/lift and 285/70 17's

    Votes: 18 3.5%
  • ARB bumper, w/lift, and 255/85 16's

    Votes: 3 0.6%
  • ARB bumper, w/lift and 315/75 16's

    Votes: 8 1.6%
  • Demello bumper, no lift

    Votes: 2 0.4%
  • Demello bumper, w/lift

    Votes: 13 2.6%
  • Demello bumper, w/lift and 285/70 17's

    Votes: 14 2.8%
  • Road Armour bumper, no lift

    Votes: 0 0.0%
  • Road Armour bumper, w/lift

    Votes: 10 2.0%
  • Road Armour bumper, w/lift and 285/70 17's

    Votes: 12 2.4%
  • All-Pro Bumper, no lift

    Votes: 5 1.0%
  • All-Pro Bumper, w/ Lift

    Votes: 16 3.1%
  • All-Pro Bumper, w/ lift & 285s

    Votes: 32 6.3%
  • Stock with Skid Plates

    Votes: 34 6.7%

  • Total voters
    509
21 - 40 of 3504 Posts

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Toyota will cover alot of stuff.....this won't be one of them.....your truck has been flying....and didn't like the landing....the insurance, on the otherhand, should cover it if you have full coverage....good luck
 

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Guys,

There are several cases out there which describe the exact same phenomenon.
I'm dealing with it too! So far, Toyota ignores it. The fact is that the tire runs into the body on full upward travel. This means that the bump stop is insufficient. YOU DO NOT NEED TO JUMP THE CAR TO HAVE THIS HAPPEN! Inspecting several vehicles, it shows that the tire clearances against the body are all over the place on this vehicle. This means, some vehicles have an issue, some not. Just inspect your front body mounts and check on the height of the rubber piece between left and right. This gives you an idea of how much variation there is...

People who have encountered this problem: please contact me with your email address. The more people we get together the more pressure we can put on Toyota to fix this issue - Thanks!
that is very interesting... thanks for the info, I will crawl under the truck and take some measurements later on...
 

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Discussion Starter #23
Toyota will cover alot of stuff.....this won't be one of them.....your truck has been flying....and didn't like the landing....the insurance, on the otherhand, should cover it if you have full coverage....good luck
My truck has never left the ground. I am not into flying. The only thing I do with this rig is trail crawling. I have many people that will stand behind me on this.
 

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I know - you get flamed here pretty quick :)
Thanks for doing the research. But the biggest frustration on this case is the way Toyota acts. I sent them a detailed 9 page report with all facts and arguments why I believe that this is a design/production issue. I want this problem to be solved. I love my truck. But no responce back except: warranty voided due to signs of impact. The signs: scratches on the body. Pretty sad argument, isn't it?
I'm so frustrated about them, that I would rather get rid of my truck now. (yes I know I will get flamed for saying that!)
For sure that this is the first and last Toyota I ever bought. And it seems there is not that much positive feedback to find about their customer service in general....
 

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Discussion Starter #25
OK, I have a question about your lifts. I've never put a lift in a vehicle and don't know much about them, so bear with me. When you install your body/suspension lifts, do you have bigger spacers for the most forward set of body mounts (right behind fromt bumper attach points)? If this is not adequately spaced, I can see where there would be lots of stress in the area where the failure occurred.
No new spacers. Only thing replaced were the coils and shocks.
 

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bernd, please get in touch with me...
it seems i do have a problem receiving emails right now. but i just sent you an email with my contact data.
 

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True, oversize tire doesn't help it. But the Toyota dealerships offer this vehicle new with 33in tires, which I run as well. I think it can also happen with the original 32 in tires. I will try to prove this...
What are you talking about. The vehicle comes stock with 31" tires, not 33"s.
 

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I did some quick searching, here and on TTORA. I think I'll look into these before larger tires:

Double Convolution Springs - Timbren Aeon Hollow Rubber Springs

I stuck with stock size BFGs even with a Donahoe front and rear lift because I feared the repercussions of the small wheel well and body mount chop. Man did I get flamed for posting that opinion way back when, but better safe than sorry. I think that gives me a bit more leeway than even stock FJs as far as the stops go.
I've been thinking about what size tire to get for the longest time... everyone tells me to go to 285 but I don't have a fuzzy feeling about it... on all my race cars I've changed the tire size i needed to make a lot of modifications to make sure i didn't damage the suspension or body...
 

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Guys,

There are several cases out there which describe the exact same phenomenon.
I'm dealing with it too! So far, Toyota ignores it. The fact is that the tire runs into the body on full upward travel. This means that the bump stop is insufficient. YOU DO NOT NEED TO JUMP THE CAR TO HAVE THIS HAPPEN! Inspecting several vehicles, it shows that the tire clearances against the body are all over the place on this vehicle. This means, some vehicles have an issue, some not. Just inspect your front body mounts and check on the height of the rubber piece between left and right. This gives you an idea of how much variation there is...

People who have encountered this problem: please contact me with your email address. The more people we get together the more pressure we can put on Toyota to fix this issue - Thanks!
Just checked on the front mounts. Mine are unequal. One being 1/4 inch shorter that the other. I'm defininitly going to see about replacing them with the ones I mentioned earlier. Thanks and rep to you for pointing that out. I was having bumper clearance issues on one side of the body at extreme flex. Very slight. Now I know why. Thanks again for at least finding my issue :)
 

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Discussion Starter #30
With only 3 of these reported out of all the FJs on the forum. It would really be nice to hear the whole story on this. This is fishy. Lot's of us wheel extensively, with the same options, and no trouble. Physics isn't random. Is there any more you might be able to tell us? It might be a rare metal defect, but it's hard to imagine.

EDIT: Read my post again. Please don't think I'm doubting your word. I'm just looking for more info. Another thought, have you had a lot of high speed rutted or washboards? Maybe it's something in the design of the ome/shock and their rates. Have you pulled anyone, or had to yank from your bumper tow points. This is so ugly and strange. Makes one a bit worried.
The whole story. Well I bought it because it was a trail rig. I use it as a trail rig. I run trails in the PNW and I took it to Ouray. I crawl over large obstacles and don't land hard. I have flexed the rig quite a bit. The trails I run with it I have run numerus times with my CJ-7 prior to buying the FJ. I'm not new to wheeling and am very sad that this has happened. I truelly love this rig and want this problem figured out before more of us see it. I only have 7000 miles on this rig. I am worried for you all also. This is not good:(
 

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The whole story. Well I bought it because it was a trail rig. I use it as a trail rig. I run trails in the PNW and I took it to Ouray. I crawl over large obstacles and don't land hard. I have flexed the rig quite a bit. The trails I run with it I have run numerus times with my CJ-7 prior to buying the FJ. I'm not new to wheeling and am very sad that this has happened. I truelly love this rig and want this problem figured out before more of us see it. I only have 7000 miles on this rig. I am worried for you all also. This is not good:(

My heart really goes out to you. What size tires are you running? Maybe we can figure out some specs to keep this from happening to any other poor souls. Inside your wheel well have you noticed a lot of rub or other indicators? This is so crappy!
 

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just measured all body mounts, they all are at 1 3/4" except for one front is at 2"...
This makes all the sense in the world now... last week I was fabing up new mounts for my new bumper and I did some measurements from the bumper mount (frame) to some of the body panels and although the mounts were the exact same the measurements didn't add up... rep points to you for pointing that out...
 

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Discussion Starter #33
My heart really goes out to you. What size tires are you running? Maybe we can figure out some specs to keep this from happening to any other poor souls. Inside your wheel well have you noticed a lot of rub or other indicators? This is so crappy!
Tires 285 70/17 BFGs. Iwas just outside looking at the wheel wells. There is no visable rubbing.
 

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My truck has never left the ground. I am not into flying. The only thing I do with this rig is trail crawling. I have many people that will stand behind me on this.
Let me start over....My rig has 12k miles on it and my gps offroad miles are at 7346 miles....so I think I can call mine a trail rig too....OME 285's ARB and warn9k to name a few mods....
every time I've jammed a tire into the wheel well the only rub spot I see is some stupid bolt that comes down from the top...I have since cut that bolt out...no mount chops...
Toyoya has been happy to give me at no charge;
3 rear diffs
1 auto tranny
1 front diff
all pulliesX3

I do run hard...but my issues have been covered because of "no obvious abuse"

I crawl Arizona desert rock on a steady basis...
I like to get to the fun stuff in a hurry.....

You don't have to go airborn to smash a tire up into the wells....but the truck does seem front heavy and bottoming out DOES happen.....

again... I am sure insurance will cover this...they replaced my roof and rack when I leaned a little hard on a rock crawlin' night run and ripped my roof on the passenger side....

your deal may or may not have been a case of "Oops I did it again".....
I just don't see it as a defect as much as a cost of being in the game...
this surely didn't happen on the hiway did it???
So I'm sorry if I offended you but (I'm going to offend you again) suck it up and move on....
call the insurance... or call air2air and see if he has the solution....to be honest...I think it'll happen again...regardless of repair....I'm kinda shocked this hasn't happened to mine yet....
:) :) :)
 

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Hopefully other owners that spend a lot of time offroad will inspect this area as a result of this Thread and report back. If these cracks start small and propagate there could be lots of folks with a developing problem that aren't even aware of it yet. It would also be interesting to find out if any of the Trail Team FJ's have cracks in this area since they have more miles offroad than most of us. Finding out how widespread these failures are and the circumstances involved would obviously help determine if everyone that does a lot of flexing will eventually have this happen, or if it's confined to modified FJC's, or there's a manufacturing defect peculiar to just a few vehicles.
 

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Discussion Starter #38
your deal may or may not have been a case of "Oops I did it again".....
I just don't see it as a defect as much as a cost of being in the game...
this surely didn't happen on the hiway did it???
So I'm sorry if I offended you but (I'm going to offend you again) suck it up and move on....
call the insurance... or call air2air and see if he has the solution....to be honest...I think it'll happen again...regardless of repair....I'm kinda shocked this hasn't happened to mine yet....
:) :) :)
I do understand the cost of this game. I don't think that the sheet metal should rip in a crumple zone just because its been driven on a trail. I have no signs of tire rub. I truely can say that I ever noticed the tire rubing. Offended me? No, I'm just trying to figure this out. I truely hope this doesn't happen to you.
 

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Discussion Starter #39
Hopefully other owners that spend a lot of time offroad will inspect this area as a result of this Thread and report back. If these cracks start small and propagate there could be lots of folks with a developing problem that aren't even aware of it yet. It would also be interesting to find out if any of the Trail Team FJ's have cracks in this area since they have more miles offroad than most of us. Finding out how widespread these failures are and the circumstances involved would obviously help determine if everyone that does a lot of flexing will eventually have this happen, or if it's confined to modified FJC's, or there's a manufacturing defect peculiar to just a few vehicles.
Yes. Please go out and look at your rigs. I am under my hood quite a bit and only noticed it today.
 

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OK...I went and took pictures of what I think is a problem with after market bumpers/body damage....

note this is the ARB bumper...the one trail teams use...

Note the size of the gap between bumper and body....at least 1 inch
note the flags on mine...still rubbing at over 1 inch gap
note the body rubs on the side

I have seen a few bumpers with the bumper smashed right up against the front grill...This WILL cause damage in the long run because the frame and the body are NOT connected(note the rubber bushing you are all talking about)
there HAS to be some play in that area
please go check your bumper and tell me if the bumper touches the grill AT ALL...or is there a gap...the gap is absolutely nessisary if your are going to flex this truck as far as some of us do....to be continued...after you gap check
 
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