Build The Fresh-Air-Ah GX 460 Build Thread

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I don't think I'm telling tales out of school here, but Alefer5 posted this on the GXOR subReddit:

Just wanted to put out a quick PSA about the “RSCA OFF” airbag switch - because I wasn’t familiar with it, and I really wish I had been.​
Despite building out my rig over the past three years, I never looked into when or why to disable the side curtain airbags.​
This past weekend at Jawbone Canyon, my 2013 GX was on about a 20° angle when the rear wheel slipped off an obstacle (roughly 12–18 inches high). The side curtain airbags, driver seatbelt, and rear driver seatbelt pretensioners all fired. Scared the hell out of me.​
Despite zero body damage and the vehicle being in impeccable mechanical condition, the dealer estimate came back at $18K in parts and $15K in labor - over $33K total, far exceeding the vehicle’s value.​

Jesus! $33k? Holy crap.

Apparently only the 2010 - 2013 models have the RSCA Off button. The newer models don't have one so I'm assuming it's done automatically.
 
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I don't think I'm telling tales out of school here, but Alefer5 posted this on the GXOR subReddit:



Jesus! $33k? Holy crap.

Apparently only the 2010 - 2013 models have the RSCA Off button. The newer models don't have one so I'm assuming it's done automatically.
You are correct, this was my post! Thanks for flagging this PSA - hopefully this can help folks down the line
 
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I don't think I'm telling tales out of school here, but Alefer5 posted this on the GXOR subReddit:



Jesus! $33k? Holy crap.

Apparently only the 2010 - 2013 models have the RSCA Off button. The newer models don't have one so I'm assuming it's done automatically.
Just read this guy's post. WOW! Had no idea replacing side curtains were so expensive. I mean like, total the vehicle, expensive!
 
This is my first post here (coming over from the FJ Cruiser Forums) and I'm happy to announce that I've acquired @alefer5 's GX 460 with the intent to repair/rebuild and keep the legend going. With a growing family, the FJ was too small for what I wanted to do with it. I have a knack for fixing things, and reached out with an offer that was accepted.

First off, everything posted about this vehicle absolutely holds up in person. @alefer5 did everything right by the book. Reading about the build here doesn't do it justice. Seeing it in person it is truly an amazing rig, one that deserves to live on, and it will.

So the next steps? I need to sort out the airbags, seatbelts, and interior bits. Although I've done tons of mechanical work on FJ's, Tacoma's, Tundras, VW's, Hondas, etc., interiors are a blindspot for me. I hold a deep belief that anything can be fixed, so right now I'm researching my options and calling all my connections in the auto industry to see what the possibilities are here. Given that next week is Thanksgiving, and I've got a business trip right after that, I'm thinking it'll be early to mid Dec before I have some meaningful updates for you guys here.

Also if anyone is looking for an FJ with a fresh engine...I know a guy who might have one for sale in 3 weeks.

IMG_2593.webp


The cousins

IMG_2598.webp

"Why do all your new cars come home on a flatbed?" - My wife


 
This is my first post here (coming over from the FJ Cruiser Forums) and I'm happy to announce that I've acquired @alefer5 's GX 460 with the intent to repair/rebuild and keep the legend going. With a growing family, the FJ was too small for what I wanted to do with it. I have a knack for fixing things, and reached out with an offer that was accepted.

First off, everything posted about this vehicle absolutely holds up in person. @alefer5 did everything right by the book. Reading about the build here doesn't do it justice. Seeing it in person it is truly an amazing rig, one that deserves to live on, and it will.

So the next steps? I need to sort out the airbags, seatbelts, and interior bits. Although I've done tons of mechanical work on FJ's, Tacoma's, Tundras, VW's, Hondas, etc., interiors are a blindspot for me. I hold a deep belief that anything can be fixed, so right now I'm researching my options and calling all my connections in the auto industry to see what the possibilities are here. Given that next week is Thanksgiving, and I've got a business trip right after that, I'm thinking it'll be early to mid Dec before I have some meaningful updates for you guys here.

Also if anyone is looking for an FJ with a fresh engine...I know a guy who might have one for sale in 3 weeks.

View attachment 4034029

The cousins

View attachment 4034030

"Why do all your new cars come home on a flatbed?" - My wife


Good luck with the fix!

The car is in great hands - I’ll be following closely to see the legacy continue. Enjoy!
 
What's needed with the airbags, seat belts, and interior bits? Not working, not there or disgusting shape?
 
What's needed with the airbags, seat belts, and interior bits? Not working, not there or disgusting shape?

At a minimum...new side curtain airbags (both sides), new sensors, SRS computer, headliner, misc vents, plastic pieces that broke when the airbag blew, and 3 new seatbelts. The system absolutely were working, up until about a month ago when they blew out on a trail under the previous owner.

I'm no interior expert, quite the opposite actually- the interior labor doesn't look too bad but the parts are not what I would call, cost effective. Also, reprogramming the SRS system to get it all to work together will be an adventure.
 
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If you bought that for what he was asking you stole it! When he first posted about his mishap I was try to figure out how I could buy it. Really nice build, congrats!
 
SRS rollout can easily total a vehicle... almost makes a AT failure look like a trivial maintenance item. IMO... heavily hit up the wrecking yard for parts
 
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Thank you for the links. Apparently the resale of used airbags is highly regulated in California (and other states)...for good reason. I found and airbag specialist in San Diego that is willing to take this on so there is some forward progress there. Now just waiting on parts to arrive (which could take 7-10 days) and for the install which could take 1-2 days.

I'm going to see if I can re-use the existing headliner as it is creased but not torn anywhere. I won't know if it's broken underneath until it's dropped so that can easily add another $2600 to this project and more time if it requires a new headliner.

Today I spent more time going through the modifications and electronics to make sure I understand them well. Being out on the trail is not the place to figure this stuff out. I also "fixed" the dent on the hood using a bug deflector the previous owner provided but did not install.

Here is the dent. It goes through the hood and into the hood skirt

IMG_2626.webp


Because it actually went into the hood skirt I couldn’t get the big deflector to line up properly as the dent was in the way.
IMG_2628.webp


A little persuasion with the heat gun basically meant the big deflector now wraps or molds itself around the dent perfectly.

IMG_2629.webp


All done and a perfect fit!

IMG_2633.webp


That’s it for now. Now just waiting on parts
 
Alright guys, this is the first update you've waiting for. It's been a busy month (Thanksgiving, Christmas, that pesky thing called work) and I've finally made some time to get into the GX.

About a week ago I got the SRS system repaired. I was able to find an airbag specialist to do the work of replacing the 2 side curtain airbags, 3 seat belts, a couple modules and resetting the SRS system to program in the new airbags & sensors to get the system to play nicely and work together. Prior to this I had discussions with the my close friends in the automotive industry about risks, costs, etc. of taking on this project. This is what they suggested.

PERSON 1 is the president of a group that owns about 18 Lexus/Toyota/Ford/Honda dealers. Being an industry guy, he said the price Lexus quoted was fair because they must fix the car to warranty-able standards. Lexus requires replacing every airbag, module, sensor, computer AND WIRING all at once. He told me he could help me with parts costs but labor costs he couldn't discount. His estimate would still be $20k+

PERSON 2 is a co-worker of mine and former automotive engineer for Toyota. A car enthusiast by nature, he actually had something similar happen to him (airbag deployment with no accident) while at a racetrack with his BMW M3. Unfortunately he never got it fixed, instead cut out the side airbag, replaced the steering wheel with an aftermarket one and sent it. Not quite the standard I wanted to rebuild this by. His estimate was $0 - "just send it."

PERSON 3 is in the auto body collision industry and was the most helpful. Says they are able to just replace the airbags and systems that deployed and reset it all to work together. Even more, he told me most places don't do this work in house and instead farm it out to airbag specialists. For liability reasons he wouldn't tell me who he used, but through some internet sleuthing I was able to find a couple airbag specialists to do the work.

So after a week of texting back and forth with the airbag specialist, I paid a deposit, he ordered parts and then we started the waiting game. Airbags & seatbelts contain explosives and can't exactly be put on airplanes and flown in overnight like Amazon. After all the parts came in, we scheduled our appointment, and I drove the vehicle down to south San Diego. Really far south, like I could see Mexico from his spot, but I was not yet in Mexico. Over the phone he had quoted 3-4 hours to do the work, but when he saw the car in person and saw the drawers in the back, he said "this may slow me down."

He was SUPER professional. He looked like he spent more time at the country club and gym than working on airbags. Before starting the work he hooked up the GX to a scan tool to verify what systems were working, what had faults, etc. He then pointed out every pending code the vehicle had (i.e. TPMS sensors) and then some less than important ones- but said everything appears to be communicating properly. So then I left him. I stayed in San Diego finding places to do work and take calls and he kept me updated with status every few hours. At 3 hours in he texted "I'm not quite at the halfway point but I have additional help coming so this should go faster." It didn't. Anyways, after waiting nearly 8 hours I got the update "It's done, everything is working great." I hustled back
to find him putting on the finishing touches.

One of the ways I saved money was through his suggestion of re-using the original headliner. As a $2500 part from Lexus and additional labor, he said if it's not actually broken he can re-use it and get a lot of the wrinkles out to make it look good. He said with enough time, heat cycles, and some extra spritzes he was confident no one would notice...for the possibility of saving $3000 I took that risk.

So here we are today. I have the GX, it has had 3 seatbelts replaced, and 2 airbags. The system starts up, does it's checks, and then fades into the background like every other car I've had with airbags. The headliner looks great- not perfect but only to me. My wife, kids, friends, etc...would never notice.

WHAT'S COMING NEXT

I've put maybe 300 miles on it total and am ready for the next set of modifications. @alefer5 did a great job making this a trail worthy rig. With my family I value more interior space (kids take up room) and am going to be looking at ways to improve that. Things I've noticed so far...

#1. The Dometic fridge is super nice but requires the rear seats to slide up to make it fit in the trunk. I love fridge and want to keep one back there but am going to look for something smaller, mabe 50-55 liters instead of the 75 beast that's back there. So if anyone is looking for a fridge or wants to trade their smaller one for a bigger one, let me know.

#2 The Drawer System - The drawer system is great but the hold downs interfere with sliding the seats back with how they are mounted in the seat rail tracks. I definitely want to keep this system and need to figure out a better way to hold the drawers down. I estimate without the full sized fridge and re-configuring the ways the drawers are held down I can get another 3" of legroom for the 2nd row. Huge!

BUT FIRST... I am taking this in tomorrow to get tuned. With 33" tires and all the armor, it's a bit slow in my hilly area. I always wanted to do this with my FJ but never got around to it. I'm going with the Overland Torque Tune (OTT) as it seems to be the most popular. Don't tell my wife.

1766032833464.webp


Beyond that I will tackle the below list of maintenance, fixes, changes, etc. till I get this dialed in.

1766033080534.webp


This is a shorter than what I'm used to working with. I may add 4.56 gears to the list if I don't meet my objectives with the tune, and I'm open to suggestions from the community, especially from @r2m who apparently lives right by me.

I'll report back tomorrow after the tune with more photos.
 
Alright guys, this is the first update you've waiting for. It's been a busy month (Thanksgiving, Christmas, that pesky thing called work) and I've finally made some time to get into the GX.

About a week ago I got the SRS system repaired. I was able to find an airbag specialist to do the work of replacing the 2 side curtain airbags, 3 seat belts, a couple modules and resetting the SRS system to program in the new airbags & sensors to get the system to play nicely and work together. Prior to this I had discussions with the my close friends in the automotive industry about risks, costs, etc. of taking on this project. This is what they suggested.

PERSON 1 is the president of a group that owns about 18 Lexus/Toyota/Ford/Honda dealers. Being an industry guy, he said the price Lexus quoted was fair because they must fix the car to warranty-able standards. Lexus requires replacing every airbag, module, sensor, computer AND WIRING all at once. He told me he could help me with parts costs but labor costs he couldn't discount. His estimate would still be $20k+

PERSON 2 is a co-worker of mine and former automotive engineer for Toyota. A car enthusiast by nature, he actually had something similar happen to him (airbag deployment with no accident) while at a racetrack with his BMW M3. Unfortunately he never got it fixed, instead cut out the side airbag, replaced the steering wheel with an aftermarket one and sent it. Not quite the standard I wanted to rebuild this by. His estimate was $0 - "just send it."

PERSON 3 is in the auto body collision industry and was the most helpful. Says they are able to just replace the airbags and systems that deployed and reset it all to work together. Even more, he told me most places don't do this work in house and instead farm it out to airbag specialists. For liability reasons he wouldn't tell me who he used, but through some internet sleuthing I was able to find a couple airbag specialists to do the work.

So after a week of texting back and forth with the airbag specialist, I paid a deposit, he ordered parts and then we started the waiting game. Airbags & seatbelts contain explosives and can't exactly be put on airplanes and flown in overnight like Amazon. After all the parts came in, we scheduled our appointment, and I drove the vehicle down to south San Diego. Really far south, like I could see Mexico from his spot, but I was not yet in Mexico. Over the phone he had quoted 3-4 hours to do the work, but when he saw the car in person and saw the drawers in the back, he said "this may slow me down."

He was SUPER professional. He looked like he spent more time at the country club and gym than working on airbags. Before starting the work he hooked up the GX to a scan tool to verify what systems were working, what had faults, etc. He then pointed out every pending code the vehicle had (i.e. TPMS sensors) and then some less than important ones- but said everything appears to be communicating properly. So then I left him. I stayed in San Diego finding places to do work and take calls and he kept me updated with status every few hours. At 3 hours in he texted "I'm not quite at the halfway point but I have additional help coming so this should go faster." It didn't. Anyways, after waiting nearly 8 hours I got the update "It's done, everything is working great." I hustled back
to find him putting on the finishing touches.

One of the ways I saved money was through his suggestion of re-using the original headliner. As a $2500 part from Lexus and additional labor, he said if it's not actually broken he can re-use it and get a lot of the wrinkles out to make it look good. He said with enough time, heat cycles, and some extra spritzes he was confident no one would notice...for the possibility of saving $3000 I took that risk.

So here we are today. I have the GX, it has had 3 seatbelts replaced, and 2 airbags. The system starts up, does it's checks, and then fades into the background like every other car I've had with airbags. The headliner looks great- not perfect but only to me. My wife, kids, friends, etc...would never notice.

WHAT'S COMING NEXT

I've put maybe 300 miles on it total and am ready for the next set of modifications. @alefer5 did a great job making this a trail worthy rig. With my family I value more interior space (kids take up room) and am going to be looking at ways to improve that. Things I've noticed so far...

#1. The Dometic fridge is super nice but requires the rear seats to slide up to make it fit in the trunk. I love fridge and want to keep one back there but am going to look for something smaller, mabe 50-55 liters instead of the 75 beast that's back there. So if anyone is looking for a fridge or wants to trade their smaller one for a bigger one, let me know.

#2 The Drawer System - The drawer system is great but the hold downs interfere with sliding the seats back with how they are mounted in the seat rail tracks. I definitely want to keep this system and need to figure out a better way to hold the drawers down. I estimate without the full sized fridge and re-configuring the ways the drawers are held down I can get another 3" of legroom for the 2nd row. Huge!

BUT FIRST... I am taking this in tomorrow to get tuned. With 33" tires and all the armor, it's a bit slow in my hilly area. I always wanted to do this with my FJ but never got around to it. I'm going with the Overland Torque Tune (OTT) as it seems to be the most popular. Don't tell my wife.

View attachment 4050433

Beyond that I will tackle the below list of maintenance, fixes, changes, etc. till I get this dialed in.

View attachment 4050436

This is a shorter than what I'm used to working with. I may add 4.56 gears to the list if I don't meet my objectives with the tune, and I'm open to suggestions from the community, especially from @r2m who apparently lives right by me.

I'll report back tomorrow after the tune with more photos.
You're more than welcome to PM me. If so, we can have an off line conversation.
Also, can you PLEASE put the name and contact info of the fellow in San Diego who did all your work?
When you post it, post here AND it in the Guide to GX 460 Builds and Aftermarket Products thread.
I may need to call him about the airbag and AFS lights on my dash.
Thanks!
 
You're more than welcome to PM me. If so, we can have an off line conversation.
Also, can you PLEASE put the name and contact info of the fellow in San Diego who did all your work?
When you post it, post here AND it in the Guide to GX 460 Builds and Aftermarket Products thread.
I may need to call him about the airbag and AFS lights on my dash.
Thanks!

Sure thing:

If you ever need airbag service I recommend:
Airbag Mobile Service Fix and Go
Alfonso - (619) 796-8785
Serves San Diego, and he's not very mobile. He needs to stay near his shop because he has to physically take some computers/modules there to his benchtop computer to test/reset them. I think he's more mobile when it comes to working at body shops.
 
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Did you get a chance to pull the codes with OBDLink? It can access those codes.
No, I haven't. I have completely forgotten about it. I'll try it next time I hop in my rig, assuming I'm not in a rush. ;)
Thanks for reminding me!
 
OTT Tune Day

From Day 1, the sluggishness of the GX caught me off guard. I had driven other Toyota V8s in Tundras with both the 4.7 and 5.7 and they always impressed me with their power and seemingly effortless acceleration. I had expected the same from the GX460. Maybe it was the heavier mods, the sliders, the drawers, 33" tires, or the skid plates...but wait. I had 33's on my FJ and I had sliders, and other mods. Sure I didn't have skid-plates, or an aftermarket bumper, but I was driving a lowly 4.0 and that...that 4.0 felt lighter on it's feet than the 4.6. So after doing some research I realized my options were a tune, or a re-gear. I have had experience in the past with re-gears. It's physics, it makes sense. But a tune? On a naturally aspirated engine? No way this would work THAT well.

After watching countless YouTube videos and reading forums posts, I did a bit of a cost analysis and decided I should start with a tune and if that didn't give me what I wanted, then move to re-gear with either 4.56 or 4.88 gears. Everyone I looked I heard about the OTT tune and there was a local tuner, TK-421 near me so I figured i'd give it a shot.

I drove over to TK-421's house on my lunch break wondering what I was in for. Is this guy going to be the real deal or some fly by night operation? As soon as I pulled up my fears evaporated when I saw a Kei truck in his drive and another person getting their Tacoma tuned in front of me.

IMG_3172.webp


After a couple minutes the Tacoma was finished and I pulled in next. Quoc Pham took a look at the rig and decided on the "medium" throttle input setting tune. It seems that OTT is the standard tune and what get's layered on is throttle sensitivty depending on weight, tires, etc.

It only took him about 5 minutes to plug in the computer, check codes, and load the tune. After a few short minutes he said "it's done, take it for a spin and let me know what you think.".

Exactly 12 seconds into the test drive, I realized I had made the right choice. The engine came alive. Throttle lag was gone. Dead pedal from 25-75% was gone. The car now wanted to get out of it's own way, and fast. This was now the Toyota V8 I remembered, and it's already an entirely difference car. More to come...
 
If you like the combination of a V8 and a tune, you'll really like the same combination with 4.56 gears :). One of the best mods I've done to my rig, albeit the most expensive. At least in my case, MPG is about the same as it was before.
 
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OTT Tune Day

From Day 1, the sluggishness of the GX caught me off guard. I had driven other Toyota V8s in Tundras with both the 4.7 and 5.7 and they always impressed me with their power and seemingly effortless acceleration. I had expected the same from the GX460. Maybe it was the heavier mods, the sliders, the drawers, 33" tires, or the skid plates...but wait. I had 33's on my FJ and I had sliders, and other mods. Sure I didn't have skid-plates, or an aftermarket bumper, but I was driving a lowly 4.0 and that...that 4.0 felt lighter on it's feet than the 4.6. So after doing some research I realized my options were a tune, or a re-gear. I have had experience in the past with re-gears. It's physics, it makes sense. But a tune? On a naturally aspirated engine? No way this would work THAT well.

After watching countless YouTube videos and reading forums posts, I did a bit of a cost analysis and decided I should start with a tune and if that didn't give me what I wanted, then move to re-gear with either 4.56 or 4.88 gears. Everyone I looked I heard about the OTT tune and there was a local tuner, TK-421 near me so I figured i'd give it a shot.

I drove over to TK-421's house on my lunch break wondering what I was in for. Is this guy going to be the real deal or some fly by night operation? As soon as I pulled up my fears evaporated when I saw a Kei truck in his drive and another person getting their Tacoma tuned in front of me.

View attachment 4051017

After a couple minutes the Tacoma was finished and I pulled in next. Quoc Pham took a look at the rig and decided on the "medium" throttle input setting tune. It seems that OTT is the standard tune and what get's layered on is throttle sensitivty depending on weight, tires, etc.

It only took him about 5 minutes to plug in the computer, check codes, and load the tune. After a few short minutes he said "it's done, take it for a spin and let me know what you think.".

Exactly 12 seconds into the test drive, I realized I had made the right choice. The engine came alive. Throttle lag was gone. Dead pedal from 25-75% was gone. The car now wanted to get out of it's own way, and fast. This was now the Toyota V8 I remembered, and it's already an entirely difference car. More to come...
Okay, considering he's local to me, at the end, how much was the whole shabang? Parts, labor.
 
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