KDSS Update.
Took the truck to the dealership (did not purchase from them) Thursday the 6th for "service or warranty repair." At least that's what I told them. A few hours later I get a call for Johnny Junior Varsity service writer telling me "rust is not covered under the warranty."
Which is total bull****. I called him on it, and he realized quickly I knew much more about a Land Cruiser than he did (thanks MUD,) so he bowed out, saying the service manager will call me later.
Service manager pretty much knew what's up concerning the KDSS issues and didn't give any promises but said he'd push for the good fight. A fly in the ointment (to them) was that I had an aftermarket suspension install, which should not make a tinkers damn.
A week passes by with no word. I follow up and am being told "Toyota may not like that the screw is close to being stripped." I counter with "If it were not rusted shut we'd not be in the position we're in now. Tell me if I need to fight this so I may prepare."
Two hours later the service manager calls and says Toyota will REPLACE the KDSS under warranty. He even said they didn't make a fuss or ask many questions about it, to his surprise.
Take Away: Toyota knows they have an issue on their hands.
They're ordering this morning and said I should have my truck back this Thursday. In the mean time, I've been through maybe 4 tanks of gas with my FJ60. It's been fun.