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2004 Toyota Hilux

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By Research the Car 5 min read

The 2004 Toyota Hilux is a robust and reliable pickup truck known for its durability and off-road capability. It’s a popular choice for both work and recreational use. Engine options for this model year include a 2.7L 4-cylinder gasoline engine (2TR-FE) producing around 158 hp and 177 lb-ft of torque, a 3.0L 4-cylinder diesel engine (1KD-FTV) producing around 161 hp and 253 lb-ft of torque, and the 2.0L 4-cylinder gasoline engine (1TR-FE). Transmission options typically include a 5-speed manual and a 4-speed automatic depending on the engine and market. Owners often praise the Hilux for its longevity, ruggedness, and simple mechanics. Common complaints include the ride quality being somewhat harsh, and the interior being basic and lacking in modern features.

Engine

2.7L 2TR-FE Gasoline Engine

  • Oil Leaks
    • Description/Symptoms: Oil leaks are reported from various locations including the valve cover gasket, oil pan gasket, and rear main seal. Symptoms include oil spots under the vehicle and a burning oil smell.
    • Solution: Replace the leaking gasket or seal.
    • Estimated Cost to Fix: $100 - $500+ depending on the location of the leak.
  • Engine Knocking
    • Description/Symptoms: Engine knocking or pinging, especially under load or during acceleration. This can be caused by carbon buildup, incorrect fuel octane, or issues with the engine timing.
    • Solution: Carbon cleaning, using higher octane fuel, or addressing issues with the engine timing (timing chain, sensors).
    • Estimated Cost to Fix: $100 - $1000+ depending on the root cause.

3.0L 1KD-FTV Diesel Engine

  • Injector Failure
    • Description/Symptoms: Rough idling, poor performance, excessive black smoke, and difficulty starting. Faulty injectors can cause uneven fuel delivery and combustion issues.
    • Solution: Replace the faulty injectors.
    • Estimated Cost to Fix: $400 - $1200+ depending on the number of injectors replaced.
  • Turbocharger Issues
    • Description/Symptoms: Loss of power, whistling noise from the turbocharger, and excessive smoke. The turbocharger may fail due to oil starvation, wear, or damage to the impeller.
    • Solution: Repair or replace the turbocharger.
    • Estimated Cost to Fix: $800 - $2000+
  • EGR Valve Problems
    • Description/Symptoms: Clogging of the EGR valve due to carbon buildup, leading to rough idling, poor performance, and increased emissions.
    • Solution: Clean or replace the EGR valve.
    • Estimated Cost to Fix: $150 - $500+

2.0L 1TR-FE Gasoline Engine

  • No Issues Found

Transmission

4-Speed Automatic Transmission

  • Rough Shifting
    • Description/Symptoms: Hard or jerky shifts between gears, especially when cold. This can be caused by worn transmission fluid, faulty solenoids, or internal wear.
    • Solution: Replace the transmission fluid, repair or replace faulty solenoids, or rebuild/replace the transmission.
    • Estimated Cost to Fix: $100 (fluid change) - $3000+ (transmission rebuild/replacement).
  • Slipping Gears
    • Description/Symptoms: The transmission slips out of gear or hesitates during acceleration. This is often caused by worn clutch packs or low transmission fluid.
    • Solution: Check and top up transmission fluid, or rebuild/replace the transmission.
    • Estimated Cost to Fix: $100 (fluid top-up) - $3000+ (transmission rebuild/replacement).

5-Speed Manual Transmission

  • Hard Shifting/Grinding Gears
    • Description/Symptoms: Difficulty shifting into gear, especially first and second, accompanied by a grinding noise. This is often caused by worn synchronizers or a failing clutch.
    • Solution: Replace the clutch, repair or replace the synchronizers.
    • Estimated Cost to Fix: $300 - $1500+

Suspension

  • Worn Leaf Springs
    • Description/Symptoms: Sagging rear suspension, reduced load carrying capacity, and a harsh ride. Leaf springs can weaken and break over time, especially when subjected to heavy loads or off-road use.
    • Solution: Replace the leaf springs.
    • Estimated Cost to Fix: $400 - $1000+
  • Worn Shock Absorbers/Struts
    • Description/Symptoms: Bouncy ride, excessive body roll, and poor handling. Worn shocks and struts reduce the vehicle’s ability to absorb bumps and maintain stability.
    • Solution: Replace the shock absorbers/struts.
    • Estimated Cost to Fix: $200 - $800+
  • Worn Ball Joints/Bushings
    • Description/Symptoms: Clunking or rattling noises from the suspension, loose steering, and uneven tire wear. Worn ball joints and bushings can cause excessive play in the suspension components.
    • Solution: Replace the worn ball joints and bushings.
    • Estimated Cost to Fix: $200 - $600+

Electrical

  • Alternator Failure
    • Description/Symptoms: Dimming headlights, a dead battery, and warning lights on the dashboard. The alternator may fail due to worn brushes, a faulty regulator, or internal damage.
    • Solution: Replace the alternator.
    • Estimated Cost to Fix: $200 - $600+
  • Starter Motor Issues
    • Description/Symptoms: Clicking noises when trying to start the engine, slow cranking, or failure to start. The starter motor may fail due to worn brushes, a faulty solenoid, or internal damage.
    • Solution: Replace the starter motor.
    • Estimated Cost to Fix: $200 - $500+
  • Wiring Harness Problems
    • Description/Symptoms: Intermittent electrical issues, such as lights flickering, sensors malfunctioning, or the engine stalling. The wiring harness can become damaged due to corrosion, heat, or physical wear.
    • Solution: Repair or replace the damaged wiring harness.
    • Estimated Cost to Fix: $100 - $1000+ depending on the extent of the damage.
  • Faulty Fuel Gauge
    • Description/Symptoms: Inaccurate or erratic fuel gauge readings.
    • Solution: Replace fuel gauge
    • Estimated Cost to Fix: $150 - $500

Exterior

  • Rust
    • Description/Symptoms: Rust, especially in areas prone to moisture and salt exposure, such as the wheel wells, rocker panels, and undercarriage.
    • Solution: Repair or replace rusted panels, apply rust protection coatings.
    • Estimated Cost to Fix: $200 - $2000+ depending on the severity and extent of the rust.

Interior

  • Air Conditioning Failure
    • Description/Symptoms: The air conditioning system blows warm air or no air at all. Common causes include a refrigerant leak, a faulty compressor, or a clogged condenser.
    • Solution: Recharge the refrigerant, repair or replace the compressor, or clean the condenser.
    • Estimated Cost to Fix: $100 - $800+

Recalls:

  • None Found

Summary

The 2004 Toyota Hilux is generally a reliable vehicle, but like any vehicle of its age, it is prone to certain issues. The most common problems are related to the engine (oil leaks, injector failure for diesel engines), transmission (rough shifting), suspension (worn leaf springs and shocks), and electrical system (alternator failure). Rust can also be a significant issue, especially in regions with harsh winters. The severity and cost of these issues vary, with some being relatively minor and inexpensive to fix, while others require more extensive and costly repairs. It is advisable to thoroughly inspect any potential Hilux purchase, paying close attention to these common problem areas.

Toyota, Hilux
Toyota Hilux 2004
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