KDSS repair

[edes300]

Hello

I have a 2005 Gx470 with 145000 miles. My KDSS light when on and I took the cover off and discovered that the entire harness had distintigrateddue to corrosion. Not sure what to do about it. I think a new unit would be very expensive but maybe one from a junkyard?

anyone replace theirs? I’m pretty handy over the years I have replaced the secondary air injection system, replaced a leaking ac evaporator and replaced my dash. I have owned this for the last 12 years and it still runs really well. Thank you for any advice.

 

[Acrad]

470 FSM is here that may help in replacement

https://lexusgxor.com/_media/general:2005_gx470_techinfo.pdf

 

[edes300]

Thank you for the reply, as you can see from the pictures the harness that's supposed to connect is totally disintegrated. The picture doesn't show the other end of the harness as I taped it up and out of the way. The black thing was supposed to be a module that the harness connects to but now its essentially gone.

 

[edes300]

from what I can tell, the part in question that is bad is the accumulator solenoid. Lexus part number 48852-60010 almost 900 dollars at the dealer. Will have to do some checking around junkyards to see if I can get one cheaper. Other concern would be trying to disconnect those corroded lines, they may disintegrate when I start working on them. Then if this all works I'll have to figure out how to bleed the system. I can believe I'm the only one that is attempting to do this. If anyone has advice please chime in to help, greatly appreciate it.

 

[Acrad]

This is 460 specific but should be mostly applicable to 470 KDSS as well.

#KDSS Info / Problems / Discussion - ClubLexus - Lexus Forum Discussion

GX - 2nd Gen (2010-2023) - #KDSS Info / Problems / Discussion - I have a 2010 Lexus GX460 bought in 8/2010. I live in Wisconsin. The vehicle has 49000 miles as of 5/2015. The vehicle has been running great until the winter of 2013/2014 when the KDSS light starts to flash from time to time. I...

www.clublexus.com

There is a service video here

Post #31

#KDSS Info / Problems / Discussion - ClubLexus - Lexus Forum Discussion

GX - 2nd Gen (2010-2023) - #KDSS Info / Problems / Discussion - I have a 2010 Lexus GX460 bought in 8/2010. I live in Wisconsin. The vehicle has 49000 miles as of 5/2015. The vehicle has been running great until the winter of 2013/2014 when the KDSS light starts to flash from time to time. I...

www.clublexus.com

 

[Acrad]

You may want to look at Carmarka

PN is superseded to 48852-60011

TOYOTA VALVESTABILIZER | 48852-60011

➤ VALVESTABILIZER by TOYOTA for $ 292.932 on CarMarka. Original spare part 48852-60011. ✔️Sales ✔️Worldwide Delivery

carmarka.com

$292.93+ Shipping

 

[edes300]

Wow, thanks for all the help, I might be able to swap the corroded electrical components over to the old unit without disconnecting it. That would make things alot easier.

 

[edes300]

Thought I should post an update of my progress. I was able to source a used unit for 150 dollars. I’m going to try to swap over the electronics and see if I can get it to work. I’m currently waiting on a new harness rebuild kit before I can finish and test it. I’m hoping this works otherwise it’s a lot more work and with all this corrosion I’m going to have trouble disconnecting all the hydraulic lines.

 

[WallaWalru]

Any update on this?

 

[edes300]

I haven't been able to start the repair as of yet. My dad was really ill and was in home hospice with us so i was too busy to start. He passed away 6 weeks ago and i'm planing to start this in 2 weeks when I have some time off.

 

[edes300]

Now I’m half way through the the repair. I was able to disconnect all the corroded hydraulic lines without damaging them using lots of deep creep and patience. Took the whole unit off and put the new unit back together. I’m going to go through the bleeding process this weekend.

 

[edes300]

 

[edes300]

Happy to report looks like all fixed. Bled the system with a pump someone else recommended on one of these forums. Car now sits one inch higher on the front but measures almost equall on all sides now.
I do not recommend the pump I bought from Amazon it failed at the end. Very hard to pump.

 

[Acrad]

Great work!!!

 

[Jstawgn]

Where did you get the harness rebuild kit? Is there a Toyota part number with it?

What is wrong with the pump? Looking back at the cheap hydrotest pump on Amazon it is only rated for 50 bar ot 725 P$I. KDSS manual mention 70 bar which is over 1000 PSI.

 

[edes300]

I bought the harness repair kit on eBay for less than 10 dollars. It’s a standard Toyota 4 pin harness. I bought the proper crimping tool on Amazon for 30 dollars.

the test pump I bought could only go to 6 bar. You are correct you’re supposed to do 2 bleed runs. First at 5bar and second at 7bar. This is to ensure you have bled all the air out. You then reconnect the sway bars and set the truck down and after a few minutes of waiting bring the pressure down to 3 Bar. The higher pressures are only to help with th bleeding procedure.

I could only pump my test pump to 4 bar. It was so hard to pump any further. I made sure there was no air in the lines and it jammed up after I did the last bleed plug. At that point I was stuck anyways so I reconnected the whole system and brought pressure down to 3 bar. So far so good.

I saw some other threads where a different pump was used but I couldn’t find a pressure gauge for that one. Good luck.

the pump I bought is a Chinese knock off of a Rothenberger test pump. It comes by various names like Vevor and Benanova. I don’t recommend it. It could fail at any point wasting your time.

 

[CarGuyCarl]

Wow! This was an awesome thread to read through. I have a 2006 sport with the light on, not sure what codes it has yet, but being a Chicago car it doesn't look much better underneath. This gives me hope for doing this repair myself once I figure out the issue.