What have you done to your 100 Series this week? (63 Viewers)

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Well my third week of ownership has been like the previous two, I've discovered more problems that need addressing! I've sort of accepted this is an overdue 200K reset to help process having to do all this so soon after buying :)

- After buying every bit of seal, moulding, rivet, dam etc required for the windscreen, my windscreen got replaced on Friday. One of the rivet holes had been drilled larger by a previous windscreen installer but all others were fine. Sadly, my installer decided he couldn't fit the moulding despite him confirming he would, so I've now got another installer who is familiar with these coming on Monday (just in time for it to start raining all week). I'm hoping and praying it can be sorted once and for all as the windscreen issues are taking a toll now.

- The rear cargo area had a large mat over the original carpet which I knew was a bit stained etc, however I realised today that it was in fact pretty damp as it seems water has been getting in which isn't ideal. I did some research and determined that it could be any of 3 different seals, and all looked pretty rough on this so I've bought the seal for the upper tail gate, the seal that goes around the entire boot opening, and then bought some bits to reseal the 3rd brake light.
Given the carpet was worse for wear and the interior needs a really good going through, I decided to pull the rear carpet out and make sure everything was okay underneath where it's been getting damp. There is some surface rust, mainly limited to the anchor points where the 3rd row seats fix into. I've got some bits to clean those areas up and treat the rust etc.
I finally moved onto seeing if I could salvage the cargo area carpet with a carpet cleaner as it was very stained and smelt pretty bad, the pics show the water after one session of multiple passes, I'll probably revisit it tomorrow if I have time after doing the rest of the car, it still will produce brown water with the cleaner without much effort!
I'll keep the cargo interior out for now until the seals come and I can sort the 3rd brake light seal just to minimise risk of any further moisture damage etc.

As you can tell, my main focus is just trying to get this thing watertight! I'll also be testing the sunroof seals so I can tick that off the leak list!

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How did you get the carpet out of the back? Was that a pain? Seeing yours has motivated me to pull it and clean mine (and vacuum all the junk under it) this weekend. Is it really just a matter of removing the 5 screws on the tailgate end? or are some of the restraints and such bolted thru the carpet and also need removing?
 
How did you get the carpet out of the back? Was that a pain? Seeing yours has motivated me to pull it and clean mine (and vacuum all the junk under it) this weekend. Is it really just a matter of removing the 5 screws on the tailgate end? or are some of the restraints and such bolted thru the carpet and also need removing?

Wasn't too bad actually! Forgive my terminology below, I don't know the correct names for the parts and I'm going off memory from earlier.

  1. Removed the rear 3rd row of seats (they were folded up)
  2. Removed the plastic inserts/guides across the boot floor and edges (where the 3rd row seats slot in), they are just held with a single hex type screw and then just need popping up/sliding carefully (have a play gently to figure out which).
  3. Remove the plastic strip trim which bridges the gap between boot floor and tailgate, it was 5 screws and and then needs popping up at each point and on both edges (go easy!)
  4. Velcro'd across the front join with the middle carpet section so it just peels up
  5. then just needs gently pulling out from underneath some of the edges but it's not tight in there so I'd like to think it shouldn't be tricky to go back in.
No seatbelts etc were fixed through the carpet, they had cut outs for those so it should be all good!

YMMV
 
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Nice work.

If anybody have a set of front shock spacers let me know!! Hunting for a set before I email Japan4x4.
Thank you. Dave is your guy (stedman@japan4x4.com).
Send him an email, he usually responds fast. Easy to work with and ships fast straight from Japan.
 
Nice work.

If anybody have a set of front shock spacers let me know!! Hunting for a set before I email Japan4x4.
Regarding AHC strut spacers…

I posted this a couple years ago…

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If you do the AHC strut spacers, be sure to check for CV boot clearance to the strut spacers brackets. Mine would almost touch the CV boot at full steering lock, on both the left and right side fronts… too close for reliable comfort.

So, at the point of potential contact, I shaved down the shock extension brackets with a flap disc, and welded through to fuse and laminate the 2 layers of steel in the bracket. Sadly, in this process, I lost the zinc plating on the shock extension bracket in that location, so I ended up prime and painting them black.

In the photo, you can see where I changed the radius in the lower right corner of the shock extension bracket. I now have 6mm clearance to the CV boot at full lock.

These AHC strut spacers from Japan 4x4 are definitely worthwhile, especially if you have a <2” sensor lift. These spacers return the AHC strut to its normal range of motion, reducing the chances of a bouncy ride.

Highly recommended.
 
Just gave it a shot with “Once a year polish” on the faded doors. Gave some shine back, let’s see how it keeps up.

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Attempted to tackle replacing the 3rd brake light seal today, removed it from the car, spent a good hour or so removing all the old foam and remnants of adhesive.

Fitted some butyl stuff rolled thinly which seemed to go on well and refitted the light and tightened up the nuts on the two studs. Added some exterior clear silicone from 9 to 3 position for added protection from the rain.

It was all going well until I revisited the securing nuts to check if the butyl had compressed enough to allow any additional tightening... (In hindsight, I should have left it as it was nicely sealed).

Sadly one of the securing studs snapped 😢

I decided to try and remove the whole light unit and just use some strong adhesive silicone type stuff instead as I was concerned the light unit would end up with a gap between it and the body, however despite making a mess with the silicone I had applied, the light unit did not want to come out!

At this point I decided to just roll with it and leave the light in place with the butyl and just hope it doesn't leak. I replaced the messy silicone sealant with a strong adhesive type silicone sealant to go around the light unit on the exterior so hopefully that and the butyl combined with the one fixing nut will keep it water tight.

We are now rapidly approaching winter here now, and we're forecast a lot of rain this week so we shall see how it fares!

If it does leak then I'll need to buy a replacement OEM unit.

Words of encouragement greatly appreciated!

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Attempted to tackle replacing the 3rd brake light seal today, removed it from the car, spent a good hour or so removing all the old foam and remnants of adhesive.

Fitted some butyl stuff rolled thinly which seemed to go on well and refitted the light and tightened up the nuts on the two studs. Added some exterior clear silicone from 9 to 3 position for added protection from the rain.

It was all going well until I revisited the securing nuts to check if the butyl had compressed enough to allow any additional tightening... (In hindsight, I should have left it as it was nicely sealed).

Sadly one of the securing studs snapped 😢

I decided to try and remove the whole light unit and just use some strong adhesive silicone type stuff instead as I was concerned the light unit would end up with a gap between it and the body, however despite making a mess with the silicone I had applied, the light unit did not want to come out!

At this point I decided to just roll with it and leave the light in place with the butyl and just hope it doesn't leak. I replaced the messy silicone sealant with a strong adhesive type silicone sealant to go around the light unit on the exterior so hopefully that and the butyl combined with the one fixing nut will keep it water tight.

We are now rapidly approaching winter here now, and we're forecast a lot of rain this week so we shall see how it fares!

If it does leak then I'll need to buy a replacement OEM unit.

Words of encouragement greatly appreciated!
Sounds like a pain, hope it seals OK! Thanks for posting about this - have a replacement for my cracked lens and any/all tips and prior experience will help.
 
Sounds like a pain, hope it seals OK! Thanks for posting about this - have a replacement for my cracked lens and any/all tips and prior experience will help.

Thanks!

If it'll seal okay until spring then I'll hopefully swap it out then. Right now I'm trying to prioritise where I spend money, most of my efforts and funds have been going towards making this watertight which is crazy really.

I'm getting a full inspection done by a LC garage in the next week or two hopefully at which point I'll be able to prioritise any bits of work needed ahead of a few thousand mile trip through Europe next summer.
 
Pulled the t-case and did new bearing and seals on the output shafts. New u joint on the rear drive shaft, a new Tom Woods drive shaft for the front. Replaced several burned out bulbs inside on the buttons. Oil change and went with Valvoline Maxlife 5-30 synthetic blend in an attempt to dry up a slight RMS leak. Ran 10 gauge wire from the battery to the cargo area and hardwired my dual compressor pump with a switch and quick disconnect on my storage system. Air ride airbags in the rear.

Getting ready for a 4 day trip to Big Bend NP.
 
Pulled the t-case and did new bearing and seals on the output shafts. New u joint on the rear drive shaft, a new Tom Woods drive shaft for the front. Replaced several burned out bulbs inside on the buttons. Oil change and went with Valvoline Maxlife 5-30 synthetic blend in an attempt to dry up a slight RMS leak. Ran 10 gauge wire from the battery to the cargo area and hardwired my dual compressor pump with a switch and quick disconnect on my storage system. Air ride airbags in the rear.

Getting ready for a 4 day trip to Big Bend NP.
How many miles do you have on your vehicle?

Just wondering how many miles it takes to wear out the bearings and seals on a transfer case.
 
Replaced the door lock actuator motor on the driver's side door. The job was a lot smoother than I expected it to be. The passenger side is starting to fail to lock sometimes now, and the tail gate is failing to unlock sometimes, so next weekend I'll replace all 4 remaining for good measure now that I know how to do it.

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The motors are available on Amazon for $11 for anybody looking for them:

 
After last week's windscreen installer decided he wanted to avoid the task of fitting the mouldings/rivets, I had a windscreen guy visit who's been doing it for 40 years and has done plenty of these thankfully.

Nearly got rained off but I pulled the pop-up marquee out the garage and the rest is history!

Turns out all of the holes were bigger than factory which is why the factory rivets weren't fixing in place properly when I tried myself on the weekend (a bit of vindication for me!). The installer had to fit large rivets and use some appropriate grade sealant but they are all looking much better and it's now firmly in situ.

I'm hoping it's now watertight but I expect it will be which is a massive weight off my mind!

PS. there is a tiny bit of flaked paint along the upper lip of the windscreen area, this is being addressed, but underneath the windscreen itself all bits of rust were fully cleaned up and treated.

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