Builds Gerry's Build thread: "If it happens again I'm buying an Abrams" (5 Viewers)

[Unrulykid]

So to summarize the last month or two...


Had the trans issues. Put a low mileage trans in it, still had trans issues. Checked all the wiring, good. Had ecm "rebuilt", still issues. Sent my ECM to LJE in cornland, confirmed my ECM was effed in the A. Bought a used ECM (MUST match part numbers, they are not cross compatible), all is well now.

The same issue can present with faulty wiring from the body to the tailgate.

A couple of years ago, my completely trouble free 2002 LX had an intermittent problem… while driving forward from a stop, the transmission would intermittently not want to shift out of first gear… had to drive home from lunch about 5 miles in first gear only.

No codes set… After much unfruitful research and puzzling over the issue, and a whole lot of entire vehicle assessment, I discovered that one of the back up lights was not illuminating. No codes set.

So I opened up the wiring in the tailgate to body and discovered that 4 wires were seriously chafed, cracked open and intermittently shorting to each other. 23 years of opening and closing the tailgate will do that to wiring that has to flex with tailgate operation.

I replaced the entire section of wire and the back up lights began working correctly. Consequently, the transmission issue of intermittently not wanting to shift out of first gear went away and has never come back.

My assumption is that the chafed tailgate wires and backup light issue was intermittently causing the backup lights to come on while I was driving forward… And PERHAPS, the PCM or transmission control module intermittently saw power across the transmission reverse switch and got confused. Thus, not allowing the transmission to shift out of first gear.

Just a semi educated guess… but problem was resolved by repairing the rear lighting wires.

Weird-

 

[MongooseGA]

I'll post a longer update here shortly but the nutshell is, I replaced the trans wiring harness (external) and 2x trans speed sensors and now 5th is working. VSC lights are still on, I have 2 new rear ABS harnesses to install, but I'll inspect the tailgate wiring as well.

 

[MongooseGA]

OK so just a week after my "all is well now" post, all became not well again.

Despite the new ECM fixing the no 5th shift issue, it was short lived. There is a much more detailed account of the testing and learning process in my thread "A750 won't shift to 5th gear". Huge huge thanks to Alex @LJE for abandoning his family for a few weeks to answer all of my questions, simplify diagnostic procedures, and generally hold my hand through the process. Honestly, I don't know if I'd have gotten any of it done on my own, and especially so efficiently. I owe you a huge favor for sure.

What we found was that the truck seemed to *think* it was in low range, probably. This would lock out 5th gear. This time around, unlike last time, the transmission didn't feel at all like it wanted to do anything when moving the selector between D and 4. No harsh downshifts either. What we ultimately came up with, was a wild yet educated guess that there was an intermittent short somewhere in the wiring between the transfer case, transmission, and ECM. I replaced the external transmission harness (P#s available in the thread mentioned above), 2x trans speed sensors, and the L4 pickup switch on the case that tells the brain "I'm in low range". I also disconnected my Lutz Auto speed calibrator module. Unfortunately, I can't definitively say which item was the fix, but I have a spidey sense that it was the harness.

I still have the same VSC lights on the dash. They're more consistent now than they had been. I just received 2 new rear ABS sensor harnesses and will install those in the next few days. If the lights get off the dash, and the trans functions for a few more weeks, I will feel confident that the issue is resolved.

Mileage is 348k? Maybe 349k now.

 

[MongooseGA]

On the tailgate kit front- My new compressor arrived yesterday and was installed in the shop today. Unfortunately in the process of installing the aftercooler on it, I over torqued the arm on the cooler and it had a gaping air leak. Poor machine couldn't get over 25PSI. So a new cooler is on its way, should be here Sunday, and I'll get those corrected panels cut and sent out to those who have requested them.

This was an initial batch offered at what I think is a really good deal. Once the v2 is out, I will create a storefront online and sell them there at a small price increase. I will also be offering other plasma cut products for the 100s and other Toyotas.

 

[LJE]

OK so just a week after my "all is well now" post, all became not well again.

Despite the new ECM fixing the no 5th shift issue, it was short lived. There is a much more detailed account of the testing and learning process in my thread "A750 won't shift to 5th gear". Huge huge thanks to Alex @LJE for abandoning his family for a few weeks to answer all of my questions, simplify diagnostic procedures, and generally hold my hand through the process. Honestly, I don't know if I'd have gotten any of it done on my own, and especially so efficiently. I owe you a huge favor for sure.

What we found was that the truck seemed to *think* it was in low range, probably. This would lock out 5th gear. This time around, unlike last time, the transmission didn't feel at all like it wanted to do anything when moving the selector between D and 4. No harsh downshifts either. What we ultimately came up with, was a wild yet educated guess that there was an intermittent short somewhere in the wiring between the transfer case, transmission, and ECM. I replaced the external transmission harness (P#s available in the thread mentioned above), 2x trans speed sensors, and the L4 pickup switch on the case that tells the brain "I'm in low range". I also disconnected my Lutz Auto speed calibrator module. Unfortunately, I can't definitively say which item was the fix, but I have a spidey sense that it was the harness.

I still have the same VSC lights on the dash. They're more consistent now than they had been. I just received 2 new rear ABS sensor harnesses and will install those in the next few days. If the lights get off the dash, and the trans functions for a few more weeks, I will feel confident that the issue is resolved.

Mileage is 348k? Maybe 349k now.

This was definitely an interesting one - not helped by the fact that Toyota's list of "things that could prevent 5th gear" isn't super comprehensive.

On the plus side, I'm actually pretty comfortable reading the electrical wiring diagrams for our trucks now, so there's that hahaha.

I'm glad that you've (hopefully!) got it all sorted!

 

[Unrulykid]

OK so just a week after my "all is well now" post, all became not well again.

Despite the new ECM fixing the no 5th shift issue, it was short lived.

What we found was that the truck seemed to *think* it was in low range, probably. This would lock out 5th gear. This time around, unlike last time, the transmission didn't feel at all like it wanted to do anything when moving the selector between D and 4. No harsh downshifts either. What we ultimately came up with, was a wild yet educated guess that there was an intermittent short somewhere in the wiring between the transfer case, transmission, and ECM. I replaced the external transmission harness (P#s available in the thread mentioned above), 2x trans speed sensors, and the L4 pickup switch on the case that tells the brain "I'm in low range". I also disconnected my Lutz Auto speed calibrator module. Unfortunately, I can't definitively say which item was the fix, but I have a spidey sense that it was the harness.

I still have the same VSC lights on the dash. They're more consistent now than they had been. I just received 2 new rear ABS sensor harnesses and will install those in the next few days. If the lights get off the dash, and the trans functions for a few more weeks, I will feel confident that the issue is resolved.

Mileage is 348k? Maybe 349k now.

Sounds like you’ve narrowed down the list of suspects…

I would be interested to know, if the individual harnesses that you replaced ring out OK with a test light or ohmmeter.
Because if they test OK, continuity is good, and your problem is still unresolved, that would mean the issue is in the harness down the line, further towards the computers and the battery. It’s rather odd to lose both rear ABS harnesses and have an issue with the transmission control module at the same time.
Do those items plug into, and share a common home run wiring harness?

I’d also like to know if there was chafing on the wire harness that caused the issue. Or if it was a mechanical impact…
Having spent several hours laying on a creeper, with a flashlight, looking up at the bottom of my truck… I have remedied several areas where chafing could have occurred, or proximity was way too close. Doing small things that hope to improve longevity.

I agree… that the ABS sensor harnesses should fix the VSC light issue.

Maybe I’m overthinking this… it’s not even my rig, and I’m puzzling.

This is an unusual situation… Not battle damage. I’m interested to see how it turns out.

 

[MongooseGA]

Replaced the rear ABS harnesses this morning. Generally an easy process, although the connection on the exhaust (passenger) side was extremely brittle. First the wires from the sensor side of the harness popped out, leaving me to do my best Cirque du Soleil and pick/pull the rest of the trashed connector out of the truck side (female).

Hooked up TS, found an existing C1336 which refers to Zero Point Calibration. I performed another ZPC and the VSC lights are now gone. Cannot definitively say if the ABS harnesses or the fresh ZPC was the actual fix. I probably should have checked codes/ done ZPC first, but it's Sunday and I have other stuff to do.

While under the truck I found a surprising amount of rust on the all new Toyota hardware holding my trailing arms in, and my rear locker cable has partially decapitated itself again. I'll need to pull the diff out again, extend those wires from the locker, and mend it with more slack than I left myself last time. There's about a 1/4" nub of wire sticking out of the top of the diff housing. I also need to replace the front diff output seal as there's a not-terrible-but-not-ignorable leak coming out of it.

Mileage is 348,780. We're heading to Knoxville next week to spend Houston's birthday weekend with another Cruiser couple, will be a good time to shake the truck down after all of this hassle in the last few months.

 

[MongooseGA]

Sounds like you’ve narrowed down the list of suspects…

I would be interested to know, if the individual harnesses that you replaced ring out OK with a test light or ohmmeter.
Because if they test OK, continuity is good, and your problem is still unresolved, that would mean the issue is in the harness down the line, further towards the computers and the battery. It’s rather odd to lose both rear ABS harnesses and have an issue with the transmission control module at the same time.
Do those items plug into, and share a common home run wiring harness?

I’d also like to know if there was chafing on the wire harness that caused the issue. Or if it was a mechanical impact…
Having spent several hours laying on a creeper, with a flashlight, looking up at the bottom of my truck… I have remedied several areas where chafing could have occurred, or proximity was way too close. Doing small things that hope to improve longevity.

I agree… that the ABS sensor harnesses should fix the VSC light issue.

Maybe I’m overthinking this… it’s not even my rig, and I’m puzzling.

This is an unusual situation… Not battle damage. I’m interested to see how it turns out.

I also want to know the answers to your questions, but at this time, I am just glad it's over and my givea**** meter is running low. But, I'll happily send the old harness to you if you'd like to test it!

Battle/impact damage is certainly a possibility with Gerry. She gets what she needs but I do ask a lot of her and have wheeled the crap out of her for fun. Honestly, that she can cruise at 80-85 straight down the road is a testament to the truck itself and the value of maintenance. My Ms has been against the idea of selling Gerry for a 200 simply because of how much of the truck is actually new. Devil you know..

 

[Malleus]

Classic case of Theseus' ship

 

[MongooseGA]

Classic case of Theseus' ship

Had to google that but yes, I'd say that's accurate.

 

[Malleus]

If you're not careful, you learn something new every day...

 

[MrJamison]

New adjustable RLCAs from TRAIL TAILOR arrived on Monday and I installed them today. They're pretty substantial pieces of metal, and the red color is pretty sweet.

No need to jack up the truck or remove the wheels. Front nuts are 22mm, rears are 24. Keep the grease zerks pointed up when installing. I do suggest adding a 90 degree zerk for the Johnny Joint. With my straight-tip grease gun, it's impossible to reach.

I noticed a tighter feel in the back end for sure. It could be psychosomatic, but I felt it leaned a little less in corners as well. Will be getting a pair of the RUCAs from Jason in the next few weeks. One thing I noticed- the tightness from the back definitely high lighted the looseness in the front. I know my lower control arm bushings and ball joints are not doing their jobs well anymore.

View attachment 2114967

View attachment 2114968

Up next (besides the RUCAs)... I need to get these new diff bushings in, and steering rack bushings. I'm still chasing a vibration coming from the front, only felt whel on the throttle above say 60-65 MPH. I've suspected the aftermarket CV on that side, but have no clicking. I also want to get those LCA bushings and BJs changed as I know they're ready.

For my own future reference, Gerry is just over 240k mileage right now.

Sorry to bump a much older post but I may have missed your answer. Did you ever figure out what the front end vibration at throttle was? I'm having the same issue also and it's driving me nuts.

 

[MongooseGA]

Sorry to bump a much older post but I may have missed your answer. Did you ever figure out what the front end vibration at throttle was? I'm having the same issue also and it's driving me nuts.

I think I ended up rebuilding all of the front end bushings and mounts, axles and drive shafts.

 

[MongooseGA]

New tailgate door lids are ready and in production! First sets will go out today for buyers who ran in to this issue. The new design will feature 2 latches per door. This will avoid the issue with the drivers side latch interfering with key cylinders on Toyota models.

Going forward, all of these kits will be sold in this design. The hinges have also been revised to lower profile barrels. All else remains the same. Still need to put together an online store.

 

[MongooseGA]

When I was under the truck replacing the wiring harnesses recently, I noticed a pretty decent leak coming from the front diff output going to the drive shaft. Not knowing how long it's been leaking, I went ahead and did a fluid change on the front diff. Used a little over 1.5 qts of Valvoline 75w90 in the flex-fill bags. Man, those things are great. No need to dig out the fluid pump, just put a 1' piece of clear tube over the nipple and roll the bag like a tube of tooth paste.

I also greased the trailing arms and drive shafts. Most of the zerks fought me to get grease in, so I will likely need to remove them soon and clean/clear them out.

I also inspected the bottom side of the truck since I really haven't looked at it much lately besides the harness swaps. Looks like my steering rack is beginning to leak. Annoying mainly because I just kicked my own ass putting poly bushings in, but I hate the poly bushings so it's not the worst thing. Also, the lines on the power steering reservoir. In fact, I should probably replace all of the engine bay rubber lines at this point. Something with engine oil is leaking on the DS, above the front diff. I wasn't able to get a really good look at where it began, though. I've also got a split UBJ boot on the driver's side. Disappointing as these are relatively recent. When the weather clears up, I'll get under the truck with the pressure washer and go to town. If it wasn't so pricey, I'd have an appointment for dry ice blasting for the entire chassis/engine bay.

I was going to reconnect the speedo calibration unit today, but when I was inspecting the wire connectors on it, I found several exposed wires, missing the insulation around them. Was this my no-5th issue? IDK, maybe. I don't really wanna think about it anymore. I've also been chasing an obnoxious heat shield rattle ever since about the time I had the cats replaced. I thought I'd found it today, in the form of a cracked ear on one of the exhaust manifold shield ears where it bolts to the engine. Due to its location, I wasn't able to get any real tools up there from below, but I was able to get a pair of long pliers with enough purchase to tweak the thin steel so it was no longer able to wiggle. Driving test reported, this was not the fix. Meh.

So Spring will be a big time for Gerry. Mileage is at 349,150. I imagine we'll be doing 5k service in just a coupla weeks.

 

[ClassyJalopy]

... Something with engine oil is leaking on the DS, above the front diff ...

Good chance it might the valve cover gasket. I have had great luck with just checking the torque on the valve cover bolts, they sometimes come loose and cause minor leaks

...I was going to reconnect the speedo calibration unit today, but when I was inspecting the wire connectors on it, I found several exposed wires, missing the insulation around them. Was this my no-5th issue? IDK, maybe. I don't really wanna think about it anymore...

I know this is the last thing you want to hear, but if you do connect the old speedo calibration thingamajig now and lose the 5th gear, this will confirm that it was the culprit all along! Anyone who ever loses their 5th gear for any reason, will then quickly jump to the conclusion of faulty speedo correction thingumabob, regardless of whether they have one or not.
Think abt all the future generations of 100 series owners who will be greatly indebted to you forever! We might even petition to make third MOnday of Janauary a national holiday to commemorate your sacrifice!
Or just may be just install a new watchmacallit and stay anonymous. No pressure.

 

[MongooseGA]

Good chance it might the valve cover gasket. I have had great luck with just checking the torque on the valve cover bolts, they sometimes come loose and cause minor leaks


I know this is the last thing you want to hear, but if you do connect the old speedo calibration thingamajig now and lose the 5th gear, this will confirm that it was the culprit all along! Anyone who ever loses their 5th gear for any reason, will then quickly jump to the conclusion of faulty speedo correction thingumabob, regardless of whether they have one or not.
Think abt all the future generations of 100 series owners who will be greatly indebted to you forever! We might even petition to make third MOnday of Janauary a national holiday to commemorate your sacrifice!
Or just may be just install a new watchmacallit and stay anonymous. No pressure.

I did consider the valve cover gaskets. They were done during my ownership but I'll have to check back for when and what mileage. Easy enough to snug the bolts up.

Yes, that is also true. But you didn't have the roller coaster of emotions that I did during that saga. You trying to give me PTSD, Abe??

Maybe I'll be nice and try it.

 

[MongooseGA]

Good chance it might the valve cover gasket. I have had great luck with just checking the torque on the valve cover bolts, they sometimes come loose and cause minor leaks


I know this is the last thing you want to hear, but if you do connect the old speedo calibration thingamajig now and lose the 5th gear, this will confirm that it was the culprit all along! Anyone who ever loses their 5th gear for any reason, will then quickly jump to the conclusion of faulty speedo correction thingumabob, regardless of whether they have one or not.
Think abt all the future generations of 100 series owners who will be greatly indebted to you forever! We might even petition to make third MOnday of Janauary a national holiday to commemorate your sacrifice!
Or just may be just install a new watchmacallit and stay anonymous. No pressure.

I did consider the valve cover gaskets. They were done during my ownership but I'll have to check back for when and what mileage. Easy enough to snug the bolts up.

Yes, that is also true. But you didn't have the roller coaster of emotions that I did during that saga. You trying to give me PTSD, Abe??

Maybe I'll be nice and try it.

Just checked, the VCGs were done at the last timing service around 305k-ish, Spring of '22.

Also, if I were to plug this speedo thing back in, and determine that was the issue all along... can you imagine how hard my palm will hit my face? And also if that is the case, please nobody tell @LJE

 

[MongooseGA]

OK, Abe @ClassyJalopy , I did a science.

Reconnected the speedo whatchamacallit, went for a drive. All systems are go!

I'll run it and if there's another hiccup, it'll be the first thing I disconnect. Time to put my skids back on.

 

[ClassyJalopy]

OK, Abe @ClassyJalopy , I did a science.

Reconnected the speedo whatchamacallit, went for a drive. All systems are go!

I'll run it and if there's another hiccup, it'll be the first thing I disconnect. Time to put my skids back on.

You da man! @LJE 's sanity is safe too!