AHC- Pogo/Air again after new globe install (3 Viewers)

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Joined
Oct 24, 2024
Threads
2
Messages
5
Location
Texas
Sorry for the long and rambling word vomit, I’m not a great writer:
-I have read ABC's and so many AHC posts but still having issues with air entrainment.
I’m having some issues with my AHC. No damping at all in the front, little in the rear. I replaced the globes in January, so probably less than 5k miles ago.
- I do have Techstream, pressures are a touch high but I need to re-index torsion bars to properly adjust to base levels.
PO did little AHC maintenance, but it had fluid(dark) and no leaks.
It had no damping but did go L-N-H as usual, quickly with no odd pump sounds.
Replaced globes and flushed/bled system(probably poorly). Everything worked perfect after that and the ride was amazing, 14 gradations on tank.
Fast forward a few months and it spent 3 weeks this June not being driven while I was out of town, also sat with a flat tire from a slow leak that it must have had during that time. After I got back in town I replaced the tires and the ride was bad, classic front end pogo with no damping.
I first tried bleeding the 4 corners. Some foamy fluid came out, then the hose slipped off when bleeding the left drivers side rear globe. I had a huge mess of AHC fluid on the garage floor before I could finally get it closed. It may have ingested air through the bleed screw then, not sure.
I got it all buttoned up and it raised to N, I drove around the block and then raised to H, seemed to go well. Then as I was backing into the driveway, the rear end lost all pressure and dropped to the L. The truck had a huge squat and so I pulled into the garage and tried to raise again. Got dreaded 1762 abnormal pressure code.
I assumed I had gotten lots of air in it and so I bled again and decided to flush again with a new can of fluid. Went through regular flush process and tried to raise it to distribute fresh fluid, it wouldn’t raise(1762 lockout). Also, the ride height accumulator did not have any fluid in it when I attempted to bleed it. Tried Active Test procedure, nothing. Direct connected pump, ran fine, disconnected pipe from pump body and direct pump drive, good fluid came out in a steady stream.
I kept clearing the code and attempting to raise it, but it would just immediately code and lockout again. Then(very angry), I cleared code again and pressed the button to raise and violently shook the truck side to side in rage, ha. The code didn’t come back, at least not while it was being shaken. It also didn’t raise at all, and coded as soon as rocking ceased.
Based on that, I jacked the back end up about 3” by the pumpkin and cleared the code and pressed button. I was outside truck and I rocked it side to side again very roughly, and it started to slowly rise. No more 1762 code, I cycled it a few times L-N-H-N-L and back.

I let it sit for a day to think about what it had done. I came back to it and bled every corner into a catch bin, then used my chamber vacuum seal machine to degas the fluid and pour back into the tank. I probably did this 8 times, and damping never happened again.
It does raise very fast, 8 seconds or less for each step, but only 6-8 gradations on the tank. Also the returned fluid when lowered is foamy. I will let it sit in low while foamy fluid lets the trapped air out, then raise to N, sit, then raise to H, sit, and then back to L, still foamy and consistently foamy with every cycle. It doesn’t appear to get better or worse.
Through exhaustive reading here, I am thinking the screens are inducing air entrainment because they are maybe contaminated with gunk from the old fluid?

The LX is my DD, so I am hoping to get it fixed asap.

I just don’t know the logic tree that the AHC ECU uses. Why would it lock out any damping ability?
Or what checks does it have that would lock out damping ability in the front, but not throw an AHC system code?
If just from air compression in the dissolved fluid, or anywhere in the system, why would the front lock out and be hard as a rock, and the back end have some damping and some give to move up and down? If it was just air and physics, it should affect front and back equally.

I will have to order more AHC fluid since I am out now from the last flush, in case I spill too much emptying the tank. But while I wait for that, is there anything I am not thinking about that it could be? With no leaks, there shouldn’t be any air able to enter the system other than at the pump, right? The screens seem like the only logical last resort to fix the air getting into the system.

On that, what’s the time estimate do you think to drain/remove/clean/replace and prime? Maybe 3 banana and 2 hr project?

I appreciate any help this fine group may have, I really love the AHC ride and do not want/cannot afford to replace with non-AHC. Thank you!
 
Good to see the long explanation -- the prize is for clarity not brevity -- so many questions get asked on this Forum with such incomplete inforrmation as to make diagnosis somewhere between unnecessarily difficult and impossible!

Conclusion:

The following are considered more likely than not:
  1. considerable air and/or nitrogen is in the system,
  2. possibility that one (or more) of the new (!) 'globes' is leaking nitrogen,
  3. if/when the 'globes' are confirmed as good, then repetitive bleeding is indicated until foam in AHC Fluid at bleeders and foam in AHC Fluid returnin to AHC Tank both stop -- and only clear AHC Fluid flows. Note: This will be difficult and frustrating due to the start/clear DTC/re-start/clear DTC/re-start etc, etc, very repetitive process caused by DTC C1762 and large amount of air (or nitrogen) trapped in the system -- perseverance is key,
  4. if AHC Fluid is judged clear of air and nitrogen and DTC C1762 persists, consider possibility of partially blocked strainers within AHC Pump sub-asssembly -- extract, dis-assemble and clean -- see REFERENCES far below,
  5. if cleaning strainers in AHC Pump sub-assembly, also extract Return Valve -- extract, dis-assemble and clean strainer and actual valve -- see REFERENCES far below,
  6. if AHC Pump Assembly is dis-assembled, replace the grommets, O-rings and seals listed below,
  7. strong possibility that ECU is receiving wrong signals from at least one Height Control Sensor circuit (meaning Sensor or Connector or Harness), -- recommend test all Height Control Sensors and replace as necessary -- cleaning and repairs of 19 years old items usually are short-lived and unreliable.
Some (but not all) answers to your situtation will be found in these very recent Posts which you have seen:

Probably you are fed up with reading threads and posts but I will take these two "Previous Posts" and all Attachments as carefully read -- mainly so that I don't have to write out and/or upload parts of that content again -- I will just refer to these two Posts as the "Previous Posts". Apologies for the repetition where it has occurred. I will add some Part Numbers in the response below -- this makes it easy look up https://partsouq.com/ or other website to see pictures or diagrams of the parts mentioned.

Inevitably, there also will be some further links to other Posts. Irritating perhaps, but these are intended to enhance understanding and will help you to DIY fix this very worthwhile vehicle and re-establish the supreme AHC/TEMS ride on- and off-road, at relatively little cost compared to a change-out to a conventional suspension!

Summary of Observations from your present and past Posts:
  • 19 years old, 2006 LX470, 240k miles, average 12,600 miles/year (20,300 kilometres/year) -- well-used,
  • Texas-based,
  • Good visible external body condition,
  • Underbody condition not reported -- Texas-based so probably rust-free?
  • Likely great condition for age and miles, but not 'as new', inevitably requires work, certainly worth restoring,
  • First AHC Fluid change since new? Should have had at least three AHC Fluid changes -- done at least every six years!
  • Debris in AHC Fluid -- particulates, gel, wear debris -- highly likely throughout AHC system with blockage potential,
  • Hub-tofender heights not reported (?),
  • Front and Rear AHC Pressures LO to N not reported, (?)
  • Height Control Sensors not mentioned (?) -- probably 19 years old -- no DTC's but erroneous signals and condition highly likely at this age,
  • Four new 'globes' fitted -- first time replacements?
  • Source, age, type of 'globes' fitted -- new OEM? new aftermarket? secondhand? -- not reported,
  • Initial good result, 14 graduations difference between "HI" and "LO" heights, good damping, good ride,
  • Vehicle not used for three weeks,
  • Possible major air ingress at the time new 'globes' fitted???
  • Rear end dropped to LO,
  • Huge squat,
  • Techstream or other suitable scanner is used,
  • Then poor ride, foamy AHC Fluid on repetitive bleeding,
  • Repetitive foaming in AHC Fluid on return to AHC Tank - not simple turbulence,
  • DTC C1762 appears repetitively,
  • No other DTC’s reported (?),
  • Active Test is not working,
  • Height Control Accumulator does not recharge – empty (no fluid) when bleeding - possible DTC C1764 but not showing on Techstream,
  • Good (?) fluid flow claimed from AHC Pump with discharge pipe disconnected,
  • DTC C1762 repeats repetitively,
  • Initially, rocking vehicle did not clear DTC C1762,
  • Jacked Rear, then rocking vehicle cleared DTC C1762,
  • Vehicle raises fast, around 8 seconds LO>N and N>HI, when AHC is working,
  • 'globes' overall have deteriorated to around 6 to 8 graduations difference between "HI" and "LO" heights,
  • Suspicions raised by Owner about strainers/screens

Diagnostic Trouble Code DTC C1762 -- What does it mean?
AHC - C1762 Highlighted.webp

Main points from the FSM wording:
  • Low flow or low pressure downstream of AHC Pump at Pressure Sensor for 0.6 seconds results in "Fall Safe Function",
  • Real time Height Control is prohibited in "Fall Safe Function"-- vehicle may stay at "N" height, or, in motion over bumps, or on gradients, may go to lowest wheel height,
  • Real time damping is prohibited in "Fall Safe Function" -- damping is fixed at setting 8 of the 16 available damping settings, no TEMS a.k.a. AVS, therefore pogo like 'ride effect',
  • Active Test cannot overide the prohibition imposed by the "Fail Safe Function".
Side-note: Unlike industrial gear pumps, there is no high pressure relief valve protection nor low pressure cavitation protection in the AHC Gear Pump. Instead the protections adopted by the AHC Pump designers is for fast response times in the event of a fault as set out for several pump or pressure or related DTC’s:

C1711 to C1713 (Height Control Sensors): 0.2 sec
C1718 (Pressure Sensor): 1 sec;
C1762 (Low Pressure Abnormality): 0.6 sec
;
C1763 and C1764 (High Pressure Abnormality: 0.3 sec;
C1751 (Pump over-run): 85 to 100 sec;
  • Each of these DTC's has it own individual, FSM-defined "Fail Safe Function" -- the details are different and important, best to read about these in the FSM,
  • All of the different "Fail Safe Functions" have in common the prohibition of real-time height control, and, prohibition of real-time damping (comfort) control,
  • If a "Fail Safe Function" has been initiated by the Suspension Electronic Control Unit (ECU), then this prohibits real-time height control and real-time damping (comfort) control,
  • The prohibition cannot be over-ridden by the "Height Control Operation Test - Active Test" -- it should not be expected to be otherwise as this would be similar to 'bridging out' a protection in an electrical circuit to defeat (unsafely) the purpose of the protection,
  • The prohibition remains in place until the DTC is cleared,
In the case of DTC C1762, if the DTC is cleared but the fault remains in place, then the prohibition will be re-imposed in 0.6 seconds after engine or AHC system starts again.
This is why a repetitive process of start/clear DTC/re-start/clear DTC/re-start etc, etc, may be enough to gain enough height which in turns builds up enough pressure to alleviate the low pressure cause of DTC C1762 in the first place (and why a small pressure spike from rocking the vehicle may sometimes help).
Diagnostic Trouble Code DTC C1762 -- What is the main cause?

  • Short answer: Low pressure at Pressure Sensor,
  • First step: Check Pressure Sensor per FSM (a faulty AHC Pressure Sensor would be highly unusual but not impossible -- so test AHC Pressure Sensor per simple procedure given in FSM extract attached to "Previous Posts" -- no need to remove Sensor, only takes a few minutes to test for completeness and confidence that the Sensor is not misleading,
  • This vehicle has recurring DTC C1762,
  • Far and away the most common cause of low pressure at a healthy Pressure Sensor and consequent DTC C1762 is gas (air or nitrogen) in the AHC Fluid,
  • There has been a major opening to replace 'globes' and a bleeding accident -- together suggesting the possibility of further air ingress in the recent past,
  • Increased gas in AHC Fluid after a three week vehicle standing period would suggest a nitrogen leak from a 'globe' or 'globes' -- check whether bubbles are more prevalent at any particular 'globe', and/or, conduct Damping Force Controlling Condition Check (16 step check) at each corner looking for differences,
  • If these are new OEM 'globes', this should be very unlikely, unless they are very long aged, and have been sitting on a shelf for years, or are non-OEM, or are second-hand,
  • Over a few months, 'globes' overall have deteriorated from around 14 graduations to around 6 to 8 graduations difference at the AHC Tank between "HI" and "LO" heights -- now at a level at which the FSM advises "replace all" (if Front and Rear AHC pressures are within FSM-specified ranges),
Diagnostic Trouble Code DTC C1762 -- What are some other causes?
  • Short answer: Low pressure at Pressure Sensor also can be caused by:
  • partial blockages of one or both strainers in the AHC Pump sub-assembly, especially the Inlet Strainer -- see well-illustrated thread linked below under the heading "REFERENCES",
  • partial blockages of the strainer in in the Return Valve,
  • partial blockages in the actual Return Valve itself, where it is meant to (dirty) divert returning AHC Fluid directly to the AHC Tank, not through the Pump gears -- see second well-illustrated thread linked below under the heading "REFERENCES",
  • discontunuities or short circuits in connectors and harnesses causing the ECU to respond in strange ways to erroneous electrical inputs -- aged Height Control Sensor circuits always are suspicious, WITH OR WITHOUT DTC's, along with harness parts damaged by exhaust heat or rock throw,
  • air entrainment possibilities on the low pressure side of the AHC Pump could occur at items marked with a Black Diamond on the diagram below -- seems unlikely given that Inlet Strainer and potential blockage is on Inlet side of the Pump, so suction head will be lost there, seems more likely that gears will churn, more fluid slip across top and bottom planes of the gears, more bypass flow along clearances between gears and carriers and walls etc -- anyway, marked items listed are best replaced if the whole AHC Pump assembly is removed for other work:
  • grommet below AHC Tank -- Part Number 47255-60010,
  • O-ring on entry to AHC Pump sub-assembly -- Part Number 90301-06012,
  • oil seal at motor joint -- Part Number -- Part Number 90311-10001,
  • O-ring at outer case covering AHC Pump sub-assembly -- Part Number 90301-70003,
  • Note: there are no pathways for entrainment of external air directly to or around the screens/strainers within the AHC Pump or within the Return Valve.
AHC Pump and Motor Layout.webp


A few notes on the AHC Hydraulic Circuits:


This components and the AHC and TEMS systems are well-described in the FSM "LC100/LX470 AHC-TEMS General Description" extract attached to "Previous Posts", also at HOME | LC100 Factory Service Manual - https://lc100e.github.io/ -- at Index, Tab to Home > New Car Features > CHASSIS > SUSPENSION > Description -- suggest re-read details of components and hydraulic circuits. One scenario (raising the vehicle) is illustrated below:

AHC - Fluid strainer locations.webp

In relation to questions, there are several points to note after studying the hydraulic circuit diagrams in the "General Description" document:
  • the screens/strainers are completely enclosed in the hydraulic circuit -- two within the AHC Pump sub-assembly Part Number 48901-60010 and one within the Return Valve which is located inside the the milled block Part Number 48905-60010 to which the AHC Pump and its Motor are attached on either side,
  • there is no opportunity for external air to enter around these strainers,
  • build-up of gel or debris in strainers causing reduced AHC Pump delivery is possible in a 19 years old vehicle,
  • Fast raise times suggest only that Height Control Accumulator works properly (when not prohibited by DTC C1762), does not indicate satisfactory AHC Pump performance,
  • significant partial blockage of strainers with gel or debris from around the system would cause reduced flow and pressure and DTC C1762 and prohibition of Active Test -- test flow from AHC Pump with discharge pipe removed MUST look as strong as shown in first picture (not second picture) in "Previous Posts",
  • if flow test is satisfactory, no need to be concerned about strainers,
  • if flow test is not satisfactory, need to remove AHC Pump assembly, dis-assemble and remove AHC Pump sub-assemby, open and remove and clean strainers, OR, after 19 years in use, replace with new OEM Toyota/Lexus AHC Pump sub-assembly Part Number 48901-60010 (Parsouq: USD183.79 plus freight plus taxes/tariffs) for better reliability and longevity,
  • if removing AHC Pump sub-assembly, also take the opportunity to remove and clean strainer in Return Valve and check that Return Valve is clear of blockages -- interference at the Return Valve also causes DTC C1762 and prohibition of Active Test,
  • Test AHC Pressure Sensor per procedure given in FSM extract attached to "Previous Posts" -- AHC Pressure Sensor failure is highly unusual but takes only minutes to test for completeness,
  • Refer to hydraulic circuit diagrams and note that rocking the vehicle causes 'shock absorbers' to act as pumps -- when this is done while during on-vehicle tests, the small pressure spike from pumping 'shock absobers' may be enough to overcome the DTC C1762 effect and enable AHC Pump to start,
  • Refer to hydraulic circuit diagrams and note that Front AHC system and Rear AHC system are hydraulically separate systems, not hydraulically connected between Front and Rear,
  • There is hydraulic connection (controlled by Gate Valves within the Control Valve Assembly) between Left Front and Right Front, and between Left Rear and Right Rear, but there is no such hydraulic connection between Front and Rear, each 'branch' is isolated by the respective 'normally closed' Levelling Valve within the Control Valve Assembly,
  • All parts of the AHC and TEMS systems are managed by the Suspension Electronic Control Unit (ECU) located under the dash,
  • Aberrant Front and Rear height behaviours are caused by wrong signals received by the ECU from faulty Height Control Sensor circuits (meaning Sensor or Connectors or Harnesses), with or without DTC's -- this results in the ECU to causing AHC Pump and Levelling Valves to match heights to the wrong signals
REFERENCES:

How to remove complete AHC Pump Whole Assembly, open AHC Pump sub-assembly and clean strainers:
Read well-illustrated Posts #1 to #15 inclusive at

AHC pump removal with pics - https://forum.ih8mud.com/threads/ahc-pump-removal-with-pics.1227554/#post-13401739 and onwards to Post #15

How to open Return Valve and clean strainer and clean Return Valve mechanism:
Read well-illustrated Posts #1 to #16 inclusive at

AHC pump assembly - bench test NG - https://forum.ih8mud.com/threads/ahc-pump-assembly-bench-test-ng.1344484/#post-15596125 and onwards to Post #16

ADDITIONAL PICTURES:
Pump Flow -- strainers clean


AHC Pump Flow - Strainers Clean.webp



Overall Pump Assembly opened, showing Pump sub-assembly and fluid flow:
AHC - Pump Arrangement and Fluid Flow.webp


AHC - Pump Housing Detail.webp


AHC Fluid path inside Pump.webp


AHC Pump Gearcase O-ring and Backup ring details .webp



Clogged Pump:

AHC - clogged pump - BigElk.webp


Return Valve Extraction:

AHC Return Valve Extracted.webp
 
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