Twice in a day, and 2 separate faults - this car is a tester. Why do I still like it?

Trying to leave work after a long day, switch key, tick, tick - no starter. After 20 mins trying to figure out where the starter motor is so I can clout it with the wheelnut spanner, it decides to start anyway. So there's a job for the weekend, I thought, remove starter and attempt recon or replace. Any advice appreciated.

But worse was to come. 2 hours later, wife returns on foot from 2 min trip to shops, says she's broken down, awful clunking noise coming from below. On reaching the blinking slug, I start her up and confirm that engine seems fine, but if I put it into gear (4WD 2lD automatic), clunk and grate from back end of engine and no power whatsoever. It feels like a detached something going round and round; I haven't had any problems with the gearbox up to now, although funnily enough I thought I heard a faint delayed clunk on applying power from stationary position earlier today.

Any suggestions, advice on where and how to start the repair, and whether it might be fixable by a beginner such as myself would be much appreciated. My confidence after replacing the bracket, fan and belts at the weekend may be useful, but not sufficient....

- (#14358) Raheem, 1 Dec 04 16:16

Unlikely that the torque converter has come away from the flexplate, but possible nevertheless. There's an access plate under the bellhousing to let you in...

But as it goes away in neutral, it sounds more like an A/T or transfer box issue. Are the front hubs on free, and is the selector definitely at 2wd, high ratio? Any chance it's stuck at a neutral position between high and low? Wondering if it's been driving around in 4x4 and the transfer case has given way...

- (#14358) david miller, 2 Dec 04 01:27

The sound doesn't entirely go away in neutral. There's still a faint grinding/meshing noise coming from somewhere down there. I'm wondering if it could have had anything to do with the seemingly poor standard of work done when the head was replaced a few weeks ago. Would the transmission/gearbox have had to be touched? I noticed myself on a visit to the garage that he'd hadn't put the vacuum pipes back properly, so I gave him the photo from Ace Answers. But even after this, the pipes weren't back on properly, because I couldn't select 4WD when I tried last week, and on examining the photo and accompanying explanation, found that the vacuum pipe that controls 4WD operation was simply not there and that the relevant pipe coming from the air pump solenoid was squeezed out of sight with a nut jammed in the end! I mention this in connection with David's comment about 4WD having been left on - not possible in these circumstances, I take it. The hubs are certainly on free.
I'm beginning to wonder if he changed the whole engine instead of repairing the head, (he had the fuel pump to change as well) and didn't reattach the gearbox properly. I think I'm getting over-paranoid here...

I'll have a look at the access plate at the weekend, or else try to find a mechanic who actually understands these machines. There must be one in Leicester (to where I've recently moved), since there are loads of Townaces and other Toyotas in this town. If anyone can recommend someone in the area, let me know. I'm back on the cycle till then. Looks like I'm going to get fit...
- (#14358) Raheem, 2 Dec 04 13:48

Just had someone look at the problem. He says it's the prop shaft between the diff and transmission - bushes gone/become detached - so it should just be a matter of replacing same. Any offers of parts appreciated.

- (#14358) Raheem, 4 Dec 04 05:48

Raheem. You might like to know that there was, a few months ago, a Townace being broken at a Japanese vehicle dismantlers in Leicester and from which I had a few parts. The location is Kent street and this is off the Humberstone road. If the vehicle is still there, they might be able to help with the parts which you need.

- (#14358) John Davis (Leics), 4 Dec 04 06:10