Time to bring my old 55 plate RAV out of retirement, after 14 years and 120K of needing virtually nothing other than service/consumables, it needs a little TLC to bring it up to standard. I've kept it road legal, but it's been consigned to occasional trips to the tip and moving appliances for the last few years. The plan for phase one was simple:
- Sort the minor non service related niggles.
- Carry out a major service.
- Overhaul the brakes.
- Upgrade the suspension and renew associated components as required (read pretty much anything I needed to touch).
- New tyres and alignment.
What could possibly go wrong?
First job was the fobs, Toyota/Lexus fob’s were crap for most of the previous decade, the turning force required to operate the ignition results in a stress fracture across the plastic where it meets the blade. My solution is cheap, simple and Chinese. £3.69 buys you a flip key conversion kit, swap the remote fob over, get the blade cut and you’re good to go... or in my case 3 trips to Timpsons and £10 lighter because they are the only people locally with a jig that will handle a curved fob and it took 3 attempts to get it right. China didn’t consider that moving the remote centrally in the fob increases the distance from the ignition pickup coil, leading to intermittent IMMO disarming, a dab of superglue later the chip was relocated to the closest edge and now works perfectly.
Then it was onto the door sensor on d/s, it’s been intermittent for a while so I had swapped it with the p/s as a short term fix after auto lock kicked in and nearly caught me out. £6.95 delivered for a used part seemed better than Toyota at £30+ new.
After that it gets really boring, full service (oil, all filters, coolant - Toyota 10yr changed out at under 5 as per schedule, gearbox and diff fluid, wiper blades, cabin filter, everything was straight forward and easy, minor weeping on rear O/S diff seal (genuine part ordered at £24 per seal... ouch
![Frown :( :(](/styles/default/xenforo/vbSmilies/Normal/frown.gif)
), fluid level wasn’t bad, so it’s not a major priority yet, PRV is free/clear. If i’m dropping the diff, then it’s getting blasted and painted, so that’s a weekend job.
Next up brakes, front discs were serviceable, just light surface rust from lack of use. I went with EBC Ultimax2’s, the brake-in coating should scrub the disc’s clean more quickly than standard pads. EBC normally include anti-squeal shims... unfortunately not for the RAV. Copperslip to the rescue - before anyone says galvanic corrosion or sensor issues it's non conductive and the sensors are sealed. For the rear's i'd grabbed Mintex discs/pads as I was replacing both, so no need to scrub up the discs. O/S went on fine, slight corrosion on the pins etc. but nothing unexpected, as soon as I got to the N/S things were a little more tricky. I managed to snap a 1/2" 21mm bi-hex socket on the wheel nut without even getting to the breaker bar stage.
After retreating to Machine Mart (first time i've needed to use the Clarke Pro warranty in over 15? years), I decided to break out some heavy weapons. The snap-on cordless impact wrench I have is underpowered, so I decided to do something I should have done 10+ years ago and buy a higher torque impact wrench. I'd prefer pneumatic, but my portable compressor is probably on the limit for anything over 250Nm and i'd need to upgrade my airline to 10mm ID anyway, my big compressor is too far away to be of use, so it was either a new airline, impact wrench and a 3rd compressor, a cordless (not ideal for the limited number of uses it will see each year), or a mains unit. I went with the Clarke own brand 450Nm mains electric version as I only need it a few times a year. Obviously this isn't high end or suited to daily use, but the claimed output of 450Nm should make short work of things like the suspension leg bolts I have to pick a fight with later. Two minor problems, it's bigger than the air versions which can limit access, but more importantly it has no concept of graduation, it's literally 450Nm or nothing which has obvious implications for bolts (it’s a WoBD) and as such will only ever be used to dismount bolts if plusgas and harsh language don’t work.
Either way it did the job, the wheel nuts lasted about a second, my smugness at wielding my new found power lasted fractionally longer, right till I was met with this:
WARNING: ITS NOT PRETTY.
I remember watching 'Titanic: 100 Years On' and i'm pretty sure bits of that were in better condition than what I had in front of me. I don't understand how/why this one corner has corroded so badly when the other three are fine, amazingly the piston still moves, its not been treated any differently than the rest of the car. Perhaps a disgruntled neighbour has been peeing on it? After cleaning it up and ensuring I wasn't about to star in my own version of Final Destination that pretty much ended the brake overhaul for today. ECP is open, but they're literally twice the price of my normal factor for a replacement calliper. I settled on a 3/4 complete brake change and sourced a replacement calliper, hose and slide pin fitting kit along with some rust remover and converter. I guess I may as well treat them all to a refurb/paint while i'm at it.
Suspension will have to wait till the w/e now and hopefully parts will be in tomorrow morning.