2004 Toyota Hilux

2004 Toyota Hilux

Overview

The 2004 Toyota Hilux is a robust and widely respected light commercial vehicle, known for its durability and go-anywhere capability. This generation of Hilux, particularly popular in many global markets, was engineered with simplicity and ruggedness in mind, contributing to its strong reputation for reliability. While generally a dependable workhorse, like any vehicle, it has specific areas that owners and technicians have noted over time. This analysis focuses on documented technical issues beyond routine maintenance, providing insights into potential problem areas for the various engine and transmission configurations available.

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Engine

2.0L 1RZ-E (Petrol)

No Major Issues

• Symptoms: No widespread issues reported.
• Solution: No widespread issues reported.
• Cost: N/A

2.4L 2L-TE (Turbo Diesel)

Glow Plug Failure

• Symptoms: Difficulty starting, especially in cold weather; rough idling.
• Solution: Replacement of faulty glow plugs.
• Cost: $100 - $250

2.5L 2KD-FTV (D-4D Turbo Diesel)

Injector Issues

• Symptoms: Rough idling, loss of power, increased fuel consumption, black smoke.
• Solution: Cleaning or replacement of fuel injectors.
• Cost: $300 - $800 per injector

Turbocharger Wear

• Symptoms: Loss of power, whistling noises from the engine bay, blue smoke from exhaust.
• Solution: Repair or replacement of the turbocharger.
• Cost: $800 - $1500

Transmission

5-Speed Manual

No Major Issues

• Symptoms: No widespread issues reported.
• Solution: No widespread issues reported.
• Cost: N/A

4-Speed Automatic

Slipping Gears

• Symptoms: Delayed engagement, slipping between gears, harsh shifting.
• Solution: Transmission fluid flush and filter replacement; potential rebuild if severe.
• Cost: $200 - $500 for fluid service; $1500 - $3000 for rebuild

Suspension

Independent Front Suspension / Leaf Spring Rear

Worn Ball Joints/Bushings

• Symptoms: Clunking noises over bumps, imprecise steering, uneven tire wear.
• Solution: Replacement of worn ball joints and suspension bushings.
• Cost: $300 - $600

Leaf Spring Sagging

• Symptoms: Reduced load capacity, sagging rear end, rougher ride.
• Solution: Replacement of worn or broken leaf springs.
• Cost: $400 - $800

Electrical

Standard Electrical System

Alternator Failure

• Symptoms: Dimming headlights, battery warning light illuminated, difficulty starting, dead battery.
• Solution: Replacement of the alternator.
• Cost: $300 - $600

Wiring Harness Corrosion

• Symptoms: Intermittent electrical faults, non-functioning accessories, dashboard warning lights.
• Solution: Inspection and repair/replacement of corroded wiring sections.
• Cost: $200 - $700

Exterior

Body and Trim

Rust on Frame/Body

• Symptoms: Visible rust, particularly in areas exposed to salt or moisture; potential structural compromise.
• Solution: Rust treatment and repair; undercoating application.
• Cost: $200 - $1000+

Tailgate Latch Issues

• Symptoms: Difficulty opening or closing the tailgate, latch not engaging properly.
• Solution: Lubrication or replacement of the tailgate latch mechanism.
• Cost: $100 - $250

Interior

Cabin Components

HVAC Blower Motor Failure

• Symptoms: No airflow from vents, or intermittent airflow, regardless of fan speed setting.
• Solution: Replacement of the blower motor or resistor.
• Cost: $150 - $350

Door Lock Actuator Failure

• Symptoms: Power locks not working on one or more doors, manual operation may be stiff.
• Solution: Replacement of the faulty door lock actuator.
• Cost: $150 - $300 per door

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Summary Verdict

The 2004 Toyota Hilux is a highly reliable vehicle, especially when equipped with the manual transmission and petrol engines. The diesel variants, while offering better fuel economy and torque, can present specific issues like injector problems or turbo wear, particularly the 2.5L D-4D. Suspension components and the rear leaf springs are subject to wear due to the vehicle’s utility nature. Electrical issues like alternator failure are not uncommon with age. Overall, the Hilux is a sound investment for those seeking a durable and capable pickup, with most issues being manageable and repairable, reflecting its robust engineering.