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Unfortunatly none of them ever posted what did resolve their incline stall issue if they ever fixed it.
Well don’t be like them, please. Interested to know what solves it for you.
 
Alright, after tinkering and testing for the last few hours I'm optomistic I may have got it sorted.

TLDR; I think the IP's on these 1HD-FTs are sensitive to being driven at RPMs outside of spec. If RPMs dip too low d/t load on the drivetrail or accessories at some point the IP cannot create the suction needed to draw fuel, especially when the pump's head is simultaneously increased d/t being on a steep incline.

I hadn't noticed this before but tonight while driving around looking for the steepest pile of dirt I could find in some nearby construction sites I realized that my idle RPM is terribly inconsistent and that its often lower than I had given it credit for. It normally would idle around 700-750 RPM but it was occasionally dropping all the way down to just below 600 RPM in drive and would only pick up to maybe 625 in neutral (spec for the A/T is 800 +/-50 with all accessories off and the truck in neutral). Once I got the truck up on an incline, with the drivetrain loaded up mid climb and the wheel turned to load the PS pump RPMs would drop all the way down around 400 if I let off the throttle. If I shifted into neutral and backed off the wheel the RPMs would pop right back up to around 600.

The idle adjustment screw wasn't even making contact with the IP linkage so I cranked it to give me dead on 800 RPM at op. temp on level ground in neutral and readjusted the kickdown cable to accomodate this change. Now (at least on my construction site dirt mound) on incline with the drivetrain and PS loaded RPMs only drop to ~725. Obviously it's far too early to call this fixed but I'm hoping to get back out to the Owyhee's next weekend for more rigorous testing.
 
Alright, after tinkering and testing for the last few hours I'm optomistic I may have got it sorted.

TLDR; I think the IP's on these 1HD-FTs are sensitive to being driven at RPMs outside of spec. If RPMs dip too low d/t load on the drivetrail or accessories at some point the IP cannot create the suction needed to draw fuel, especially when the pump's head is simultaneously increased d/t being on a steep incline.

I hadn't noticed this before but tonight while driving around looking for the steepest pile of dirt I could find in some nearby construction sites I realized that my idle RPM is terribly inconsistent and that its often lower than I had given it credit for. It normally would idle around 700-750 RPM but it was occasionally dropping all the way down to just below 600 RPM in drive and would only pick up to maybe 625 in neutral (spec for the A/T is 800 +/-50 with all accessories off and the truck in neutral). Once I got the truck up on an incline, with the drivetrain loaded up mid climb and the wheel turned to load the PS pump RPMs would drop all the way down around 400 if I let off the throttle. If I shifted into neutral and backed off the wheel the RPMs would pop right back up to around 600.

The idle adjustment screw wasn't even making contact with the IP linkage so I cranked it to give me dead on 800 RPM at op. temp on level ground in neutral and readjusted the kickdown cable to accomodate this change. Now (at least on my construction site dirt mound) on incline with the drivetrain and PS loaded RPMs only drop to ~725. Obviously it's far too early to call this fixed but I'm hoping to get back out to the Owyhee's next weekend for more rigorous testing.
Very nice!
 
Allow me to catch you up on what's happened with the truck this summer... I decided to wait on lockers and a front bumper for a bit to get a roof rack and RTT so my wife, son, and I can start using it for all sorts of multiple day adventures. I bought a Sherpa rack and a cheap Topoak roof top tent and as these were being shipped I needed to address a couple issues before installing them. The paint around the sunroof was the only part of this truck that was obviously not minty. The plastic bubble that had been mounted up there had rubbed through the paint completely in several spots leading to some surface rust and had scratched the paint quite a bit everywhere inbetween. At some point the prior owner slapped on some touchup paint here but this job left lots of room for improvement.
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I set up an awning (unfortunate foreshadowing) to provide some shade to keep myself and fresh paintwork out of the heat and direct sunlight and got to work.
 
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Removed the spotty touchup paint with a razorblade and some tape to prevent scratching/cutting into the factory paint.

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Then used a scotchbrite pad to lightly remove some of the surface rust that had formed.

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Next took a pad with a bit of compound to remove a bunch of light scratches and years of grime that had melded in with the surface of the paint.

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Followed the sames steps on the front and other side and was left with this.

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Used some 1000 grit sandpaper and a dash of paint prep solvent to prep the metal and surrounding factory paint/primor for some fresh paint. I used Automotive Touchup primer, color, and clear coat as they were easy to get color matched touchup paint for this Toyota white color. New primer went over the bare metal and once dried this new primer was lightly sanded.

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Next up was the 045 color coat and it was time to see how close their color match actually is. I applied the paint with their tiny applicators that are basically Q tips for ants which made keeping the touchup paint isolated to just the repair area easy.

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With a light sanding.... damn, that actually is looking pretty damn good for a quick DIY touchup job!

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I was super stoked on how this turned out. This was meant to be just a "good enough" job to keep the roof from rusting any further. This was going to be covered by the roof rack and would not be visible. This had no right to turn out looking as good as it did. I left the awning up to let the paint cure out of direct sunlight and our local ski resort announced they were doing a last minute late season final day so we packed up and left to go ski one last time for the season while the paint dried....
 
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As we were driving back from skiing it suddenly got very windy and my heart sank. We were still 15 minutes away from home and I knew the awning I left up over the drying paint wouldn't likely survive the wind. My wife pulled up the camera we have on our garage and my fears were confirmed.

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As you can see from the photo it was a blue sky, warm, calm day... other than the random burst of wind that collapsed the awning into the roof. As soon as we got home we got the awning off the roof and surveyed they damage.

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:bang:“$%@:bang:“$%@:bang:“$%@:bang: - puts it lightly...

It's one thing to cause damage while wheeling. While that is frustrating, it at least ends up being reminders of good times had. This was just stupidity. Why did I leave the damn awning up? The paint would have cured just fine without it. Why didn't I check the weather before we left? It would have taken two seconds! I just turned a quick DIY paint repair purely meant to prevent rust into thousands of dollars in paint damage.
 
After stewing on my screw up for quite a while my options were to either attempt a similar DIY fix as what I had just done, take it to my father-in-law across the state and have him help me do a more professional DIY respray of the roof and rear quarters, or file an insurance claim and let a local shop repair it. By this point the roof rack and tent were both sitting in my garage and we had a trip planned for the cruiser in just over a month.

I didn't feel I had the capabilities to do this level of DIY paint repair work myself. Taking this to my FIL would have taken a couple months to repair between transporting it across the state and finding the time between our work schedules to be able to repair it in our free time.

I ended up deciding to submit an insurance claim on it. I've never filed and insurance claim on any vehicle but figured that I pay a lot for the agreed upon value coverage I have with Progressive and that this level of repair work likely justified a claim. I spent days going around talking to a bunch of shops about the repairs necessary trying to find a local shop that I felt would take the time do the repairs right.

One shop stood out from the rest, they had studies they could quote and submit to insurance to show that only new OEM replacement parts would be sufficient and that a full panel edge to edge clear coat would be required for maximal longevity. They were confident they could get progressive to cover importing parts through Partsouq and had experience doing so in the past.

They seemed to be the obvious choice.
 
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I took the swingouts off the rear bumper to make removal easier on the shop and to reduce the likelyhood that they might damage something during dissassembly or reassembly. Turns out my spindle seals have not been sealing very well.
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I also never painted the latch/handle of the swingouts which turned out to be a mistake and rust has quickly invaded. I ordered up new seals and bearings from 4x4 labs and will be cleaning up all this rust while the truck is in the shop. It turned out the spindle seals had gotten folded over during assembly and weren't properly sealing. Easy enough of a fix once I get the truck back.

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Early in the teardown the shop found some rust behind the windshield seal, and its not great.

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They said the rust extends down into the firewall. I asked if they could just cut this out and repair it while it was already torn apart which they declined doing. They apparently can't touch it if it involves the firewall. Unfortunately, for now, this is going to have to be left alone. Next time the windshield needs to come out, however, I will be cutting this out and patching with either grafts from a donor body or hand bent sheat metal.
 
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All said and done the shop billed Progressive $8100 for the repairs. I got my truck back and at first glance it looked great. Hoped in and started driving home and noticed the first issue half way home. The grab handle was broken.

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Easy enough, I'll just let them know it got broken during the repair process, I'm sure they'll replace it no questions asked. Better just give the whole truck a close lookover once I'm home to make sure there aren't any other problems before I message them.
 
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Boy was a disappointed once I got home and actually started looking at their work closely... I won't post all the photos but a quick overview of defects from their work:
  • Broke both left and right fender flares and appears to have attempted to hot glue them back together
  • Chipped paint off right fender flare and did not repair
  • Sprayed clear coat over dirt in the rear hatch jamb, in fuel door opening, behind taillights, and around rear quarter mouldings
  • Didn't clean grease from around rear door striker plate and clear coat fish eye'd
  • Broke alignment pin off of, damaged chrome strip, and ripped a chunk out of rear quarter panel mouldings (NLA)
  • Installed quarter panel moulding crooked
  • Burned through color coat in rear hatch jamb and did not repair while already painting the roof
  • Overspray in sun roof opening
  • Scratched new paint while installing drip rail moulding and did not repair
  • chipped paint between fuel door and panel and did not repair
Here are a couple of example photos of these defects.

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Perhaps I'm being nitpicky here but I didn't expect to have problems like this with an $8100 job to just pain the roof/quarters. I reached out to them with my concerns and it was like talking to a brick wall. They claim all of this was there before and was the result of a prior paint job. Only after I brought it back in person and showed them I could wipe the dirt off with a rag right next to where they painted over dirt did they start to accept responsibility for some of the defects. As of today I've taken it back to them on four separate occasions for them to repair issues and every time I have taken it back they have broken or damaged something else and either tried to hide it or not disclosed it. Won't be letting them touch it any further and will just repair the rest on my own.

If you happen to have a lead on where I could buy replacement VX Limited rear quarter panel mouldings I would greatly appreciate it.
 
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Once the fresh paint had a few weeks to fully cure I mounted up the Sherpa La Sal rack. I had one of these on my old FZJ and loved it. Second rack I've had from them and I'm just as pleased with this one.
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Reassembled the swingouts after some rust removal with the fresh bearings and seals making sure the seal didn't fold over itself this time around. Got the Topoak tent mounted up and after several trips in it, I'm quite happy with it for the money. At some point I'll need to build a hoist to make taking the tent on and off easier since its 160 lbs.

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I'm not a big fan of decals normally but I do love the factory "Turbo" decals that have been removed from my truck at some point in its life. Ordered up a set of OEM decals and did my best to get them installed in the propper location and alligned correctly with some masking tape as a reference.

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As we were driving back from skiing it suddenly got very windy and my heart sank. We were still 15 minutes away from home and I knew the awning I left up over the drying paint wouldn't likely survive the wind. My wife pulled up the camera we have on our garage and my fears were confirmed.

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As you can see from the photo it was a blue sky, warm, calm day... other than the random burst of wind that collapsed the awning into the roof. As soon as we got home we got the awning off the roof and surveyed they damage.

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:bang:“$%@:bang:“$%@:bang:“$%@:bang: - puts it lightly...

It's one thing to cause damage while wheeling. While that is frustrating, it at least ends up being reminders of good times had. This was just stupidity. Why did I leave the damn awning up? The paint would have cured just fine without it. Why didn't I check the weather before we left? It would have taken two seconds! I just turned a quick DIY paint repair purely meant to prevent rust into thousands of dollars in paint damage.
Don't beat yourself up too bad. I can't tell you the times that my own OCD has bit me on my cruiser. Not saying you are OCD but most of us love our trucks, at least I do. That tends to make out standards a bit higher than John Q Public.

Bummer about the shop but you did all your due diligence ahead, nothing more that you could do.

The truck looks good and the silver lining is you discovered small problems (rust) before they became big problems.
 
Finally got back out to the feature on Lost Trail that gave me issues with stalling months ago. I can now say with confidence that my idle speed was just too low for the the IP to draw fuel on the steep incline. Zero issues today with 800rpm.

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With a Moab trip coming up next month, I left the tent on for today's run to get a feel for how it would impact wheeling ability. As a surprise to no one, it was worse.

4x4labs earned it's keep today keeping the quarter of the rocks. Front bumper and rear door flare justed kissed rocks with the extra lean angle from the tent being up there. Luckily only light scuffs there. The extra weight up high made climbing steep rock slabs much harder which I didn't expect. Had way more wheel spin today than usual.

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