Lower control arm bolt snapped .. while the car was parked

[halifaxyaris]

While stopped for gas in Maine this week (on vacation), I heard a pop/snap. Looked under the car I noticed a bolt head snapped off. I didn't immediately spot the problem until I went over a bump and braked. I looked under the car while the front weeks were turned and noticed the lower control arm, separated from the frame. 7.5 hours of labor, and $10.50 in parts, I'm back on my way. Thanks to Oregans Halifax, and Breton Toyota Sydney, for not looking out for me. This could have been clearly avoided if the service people were a little pro active, and simply replaced the two bolts before they snapped off. The car has 97,000 km and has always been dealer serviced ( including a recent MVI ) Shame on Toyota for using sub standard parts. Clearly a recall should be in the works.

[Viperoni]

Pro active on replacing bolts that are not wear items in any sense and should have never failed like this to begin with?

I do agree with weak bolts though, there's a couple engine bay bolts that I've loosened that snapped which should not have under the pressure that they did. A suspension bolt should be at least a Grade 8 bolt and normally doesnt' break unless other conditions are present (like it's loose for some reason).

[CTScott]

There is a TSB for those bolts corroding and snapping.

[yaris2010RS]

There is a TSB for those bolts corroding and snapping.

i thought the issue was only on the early 2007's

[CTScott]

2007 - 2011

43341

[marcus]

i was at toyota a month ago for my water pump howcome they didnt tell me about this..??

[CTScott]

i was at toyota a month ago for my water pump howcome they didnt tell me about this..??

Because a TSB is not a recall. It is an informational document that saves technicians troubleshooting time on known issues.

[MUSKOKA800]

So it's a lot more than a bad bolt if a whole component need be replaced.
OR that bolt was under-torqued and the resultant free-play would damage the other pricey part.
Thankfully my out of warranty 2008 sedan has exibited no such pricey clunk.

[yaris2010RS]

ooo im gonna go to toyota and say my car is clunking

[CB900F2]

Scott.. Where did you find the TSB??

Thanks Scott

2007 - 2011

43341

[CTScott]

Scott.. Where did you find the TSB??

Thanks Scott

TIS

[Viperoni]

So it's a lot more than a bad bolt if a whole component need be replaced.
OR that bolt was under-torqued and the resultant free-play would damage the other pricey part.
Thankfully my out of warranty 2008 sedan has exibited no such pricey clunk.

WOW they recommend a new cross member along with new CA's and a particular bolt. Damm.

Sounds like the bad bolts wear a hole into the CM as they break or something along those lines. Interesting.

At this rate you guys might as well get those bolts swapped out before they break so you don't have to go through the extra expense, shouldn't take more than 20 minutes on a hoist.

[MUSKOKA800]

Perhaps I spoke too soon!
Clunking started Wed. afternoon. I'll run it up the ramps tomorrow and investigate. Sounds like the symptoms in the TSB. Clunk when braking, then clunk with re-accellerating and clunk over bumps.
Of course my warranty is done and it doesn't look like a driveway job.
Cha-ching!!! This may be our first trip to the service department. :(

Update: Sure enough, the head of the drivers side control arm rear bolt is gone. It broke off at the head so the stud is still intact so the arm cannot become dislodged.
I'll investigate other more reasonable solutions on Monday as the TSB is a very pricey process.

[MUSKOKA800]

Update:
Visited Burlington Toyota/Scion this afternoon.
In Canada the TSB includes only the new, improved bolts. No new cross-member or control arms are specified. Approx. 3.5 hours (at $98.00 per hour) labour plus an alignment at ~$99.00. The bolts are ~$8.50 each.

Tomorrow an independant shop will investigate whether they can remove the broken bolt without dis-assembling the front end. Welding a large nut to the bolt shaft may be an option. A much cheaper one.

[Viperoni]

Update:
Visited Burlington Toyota/Scion this afternoon.
In Canada the TSB includes only the new, improved bolts. No new cross-member or control arms are specified. Approx. 3.5 hours (at $98.00 per hour) labour plus an alignment at ~$99.00. The bolts are ~$8.50 each.

Tomorrow an independant shop will investigate whether they can remove the broken bolt without dis-assembling the front end. Welding a large nut to the bolt shaft may be an option. A much cheaper one.

I was gonna say that welding another nut/etc onto the existing piece should do the trick if there's enough material protruding past the subframe.

Keep my fingers cross for ya!

[fnkngrv]

sounds like a crappy TSB for sure!

[MUSKOKA800]

Thanks to Corporate Autoworks in Burlington!
Today they easily removed the broken lower control arm bolt using an air chisel to turn it out far enough to grab it with vice grips. Then they cut a screwdriver slot in the end, put on some never-seize and re-installed it so I can nurse it around town for another day.
Two updated bolts will be delivered tomorrow by Burl. Toyota for installation at Corporate Auto.
I'm looking at approximately one hour of labour, two bolts at $8.50 each and no need for another $100.00 alignment.

Update: Today's final total incl. removal of the old and installation of the new updated parts = $135.00

Advice to all... order the bolts and replace yours now. You can do it yourself for about $20.00 before they break.

[Viperoni]

Thanks to Corporate Autoworks in Burlington!
Today they easily removed the broken lower control arm bolt using an air chisel to turn it out far enough to grab it with vice grips. Then they cut a screwdriver slot in the end, put on some never-seize and re-installed it so I can nurse it around town for another day.
Two updated bolts will be delivered tomorrow by Burl. Toyota for installation at Corporate Auto.
I'm looking at approximately one hour of labour, two bolts at $8.50 each and no need for another $100.00 alignment.

Update: Today's final total incl. removal of the old and installation of the new updated parts = $135.00

Advice to all... order the bolts and replace yours now. You can do it yourself for about $20.00 before they break.

Glad yours wasn't pricey.

I also agree with the last line 100%, it's an EASY job and will save you $$$$$ down the road.

[Hershey]

Our '08 sedan has been clunking at times for over a year now . We made and took a copy of the TSB for CANADA to a service center and showed the service manager . We told him of the noise and we're concerned only to get a rude reply of " That's for CANADA not here and there's no need to take a look at it " ! This was the same service department that did the head cylinder gasket replacement . Sounds like TOYOTA is trying to take the cheap route by only doing a T.S.B. and not a RECALL . Most likely would cost them a bundle for the repairs and rather lay it on the consumer and the elements of nature . Not shocked , since the issue we went through with TOYOTA corporation about the head cylinder gasket issues of the '08 we still have and the 2010 3 door we no longer own .

[johnny_vitz]

Our '08 sedan has been clunking at times for over a year now . We made and took a copy of the TSB for CANADA to a service center and showed the service manager . We told him of the noise and we're concerned only to get a rude reply of " That's for CANADA not here and there's no need to take a look at it " ! This was the same service department that did the head cylinder gasket replacement . Sounds like TOYOTA is trying to take the cheap route by only doing a T.S.B. and not a RECALL . Most likely would cost them a bundle for the repairs and rather lay it on the consumer and the elements of nature . Not shocked , since the issue we went through with TOYOTA corporation about the head cylinder gasket issues of the '08 we still have and the 2010 3 door we no longer own .


All car company's do this, nothing new. Your head gasket issue was a very rare case, maybe you got the bad one. Please stop bashing toyota... :thumbup:

[Hershey]

When it's our money spent on many of their cars over the years you have the right to be peeved with TOYOTA and the way they and some of their service centers handle issues . Believe what you want , your right . Last , we do enjoy the '08 sedan while it has had issues . Plan to keep it until the bitter sweet end . It's a love / hate relation .

[johnny_vitz]

I'm glad you still enjoy the sedan. Some dealerships are a pain to deal with, they're all different.

[Hershey]

TOYO service took it for a spin to listen for the clunk , no noise . Then put it on lift and said it all looks good . Did notice the bolts are rusted and said it's the norm for our region . We'll have to wait until it clunks most or all of the time for next visit .

[Kioshi]

So they are just grade 8 bolts like the ones at Lowes and Home Depot?
I will go into the dealership and ask them about it next month....

I have no room in this one car garage, so I'll take it to a repair shop and have them do it.

[MUSKOKA800]

TOYO service took it for a spin to listen for the clunk , no noise . Then put it on lift and said it all looks good . Did notice the bolts are rusted and said it's the norm for our region . We'll have to wait until it clunks most or all of the time for next visit .

The clunking begins only after the head of the bolt shears off allowing the lower contol arm moves back and forth during braking and accelleration.
DO NOT wait until they break to replace them. The bolts cost $8.50 each (at Canadian dealerships, likely cheaper in the US) and can be replaced with hand tools until they break at which time the cost/complication of removal/replacement will greatly increase especially if you enroll a dealer to process the TSB. DON'T WAIT! Save several hundred dollars. Do it now.

[MUSKOKA800]

So they are just grade 8 bolts like the ones at Lowes and Home Depot?
I will go into the dealership and ask them about it next month....

I have no room in this one car garage, so I'll take it to a repair shop and have them do it.

Although I didn't see the new bolts before my mechanic installed them I would think that they have a stepped head judging by the configuration of the control arm mounting point. Best go to your dealership and buy their upgraded parts for less than $20.00 for both and know they're correct.

[Hershey]

Same here , no garage . Driveway is too sloped to work on .

[yaris2010RS]

hey hershey! hows it been going, havent seen u on the fourms for a while.

so i have recently noticed a clunking noise coming from my car, i notice it more if im stopped while turning the wheel vs when im changing from forward to reverse. i will be going under the car tomorrow to take a look and ill pick up the new bolts from toyota on monday. are the new bolts a better design/material or is it the exact same bolt but just buys you some time before it breaks again?

[yaris2010RS]

2007 - 2011

43341

also from looking at this TSB it says we need more then just the bolt? is this correct? im afraid to have toyota do the job under warranty as my car is lowered and is quite other wise moddified

[MUSKOKA800]

also from looking at this TSB it says we need more then just the bolt? is this correct? im afraid to have toyota do the job under warranty as my car is lowered and is quite other wise moddified

The Toyota Canada TSB showed only bolt replacement for my '08 sedan. No mention of control arm or cross-member replacement and about 3 hours instead of the 5.5 hours stated in the US TSB. Other production years or models could differ of course.
The bolts are supposed to be an updated part. Hopefully that means better.

[yaris2010RS]

it takes 3 hours to replace a bolt???

[MUSKOKA800]

it takes 3 hours to replace a bolt???

Only at Toyota, after they've broken.
My mechanic replaced the one broken and other still intact bolt in about an hour. My total cost for parts and labour (two visits) ~$130.00.

Strange. I found the broken bolt head and washer in my parking spot at school this morning. Odd that it would have snapped while parked. The bolt was clearly defective with rust extending better than halfway through it's half inch shank, right at the head where the flat washer would be.

[taka]

Replaced both bolts with new which look identical to the old one. Maybe Toyota already had the new type bolts installed? The old bolts shank are rusted on the bottom 1" near the washer. Looking at the installation area, it form a bathtub shape trapping water where the bolts are. There drain holes further back but are higher up. No wonder the TSB called for sealing seam that area. I covered the bolt shank with lots of grease to prevent corrosion before installation since I can't seal due to undercoat.

[GregP42]

I am glad I saw this thread as it now tells me what to look for under my '08 for the clunking noise I have had.

[marcus]

anyone know the part number for this bolt??

[CTScott]

anyone know the part number for this bolt??

There are three or so threads on this now. The part number is posted in the "warranty" one.

[fnkngrv]

Just received a warranty extension for this bolt issue to 7/100k.

[UberSilver]

anyone know the part number for this bolt??

90119-14126:smile:

[marcus]

90119-14126:smile:

thanks bro but is this the new one or the old bolt part #..

[CTScott]

thanks bro but is this the new one or the old bolt part #..

The old and new are really the same. There isn't a new part number. When I bought six of them, the new ones all had different markings on the head than the old ones, but that may just have been because they were a different batch.

[marcus]

cool .. thanks i did notice 1 marking on the new bolt vs 2 markings on the old one..

[UberSilver]

cool .. thanks i did notice 1 marking on the new bolt vs 2 markings on the old one..

My old ones had two line marks, as did the new. Would have been nice if Toyota released a stainless steel bolt as the replacement.:frown:

[andulong]

I want to swap out my bolts before they break. I do most of my own work but have not messed with suspension stuff much. Is this just as simple as lefty loosey...righty tighty? I have a 3/4" metric socket set and a beam torque wrench and think I can slide under the car if I park it on the curb. Anything special needed? Grease, sealant...or just new bolts and wrenches?

$20 for bolts will give me a lot of peace of mind down the road...even though I am in San Diego and the bolts look fine at this time.

Just hope they don't break off during removal...if so then I never touched them!

Thanks.

[CTScott]

I want to swap out my bolts before they break. I do most of my own work but have not messed with suspension stuff much. Is this just as simple as lefty loosey...righty tighty? I have a 3/4" metric socket set and a beam torque wrench and think I can slide under the car if I park it on the curb. Anything special needed? Grease, sealant...or just new bolts and wrenches?

$20 for bolts will give me a lot of peace of mind down the road...even though I am in San Diego and the bolts look fine at this time.

Just hope they don't break off during removal...if so then I never touched them!

Thanks.

Chances are that yours still look like new, but it is as simple as cranking out the old one and cranking on the new ones.

[Hershey]

Think we'll just let it go and check on the bolts when doing an oil change . Hopefully one will snap off before the 8 yr. / 125,000 mile warranty expires . Think we have 3 years after this MAY or 68,000 miles . 3 years is most likely .

[RedRide]

Its my understanding that this is more of a problem in northern areas where salt is used on snow and ice .

I got my extended warranty notice a month or so ago. So far, the bolts are fine on my '09. Even though I live in NY state, since I have retired, I rarely dive on icy, sated roads any more.

[marcus]

now im scared to even take the old one out....sigh*

[NEexpat]

OK, so,

Some Yari left the factory, (factories) with what was later determined to be inferior quality bolts that may or may not be susceptible to accelerated corrosion and failure due to what only can be described as a design flaw in the shape of the lower control arm. Causing water and moisture to pool.

The only way to see if your cars bolts are corroding is to remove them and do a visual inspection. Unless of course the head of the bolt shears off then you'll know.

Bringing it in to Toyota they will what? Tell you they can't do anything until it shears? Look at the bolt heads? And if the heads are fine they do nothing or do they remove them them inspect them and then ...........what?

Do they, will they. replace them if they have gone that far or put the old bolts back in? At what level of rust or corrosion?

(At first I thought this was limited to some Yari from some factory with some paticular batch of bolts, but it appears to be more widespread. Not bolts, design).

However if they shear off bring it in and they'll fix it and have extended the warranty on this issue, unless your car is over 100k miles or 7 years or something, or you have an extended warranty beyond that, that may or may not extend to that depending on the mood of your service manager..............maybe.

And they will fix it with what? Bolts that are less susceptible to corrsion? Salt water corrison in particular?....................................... ............. FIN?

Or is this something that is going to have to be addressed for the life of the car? How does this address the design flaw?

Does that about sum it up, what have I missed? Just trying to understand this....................completely.

I'm in the Northeast of the States, my car has just under 40K and when I wash it off in the winter I always try to rinse the undercarriage with the wand more than usual. I looked at my bolt heads and they seem fine to me, of course the problem lies just beneath the bolt head.


HA! And I thought when I bought that 19mm socket to do my cruise control DIY that I would never use that again.

cheers.

[Hershey]

It's been at 2 service centers and both said it's fine . Proboably don't want to be bothered with it . TOYOTA should make it mandatory to change the bolts . It's cheaper for them to leave it up to the mechanics .

[Bigs]

So I have an 08 Hatchback. According to the TSB listed early in this thread, after a certain VIN (JTDJT4K3#B5330321 or JTDKT4K3#B5330321) this “shouldn’t” be an issue.
My VIN is JTDJT92388520XXXX, so am I in the clear?
I think so but also thinking about preemptively changing the bolts.

What do you think?
Thanks

[CTScott]

So I have an 08 Hatchback. According to the TSB listed early in this thread, after a certain VIN (JTDJT4K3#B5330321 or JTDKT4K3#B5330321) this “shouldn’t” be an issue.
My VIN is JTDJT92388520XXXX, so am I in the clear?
I think so but also thinking about preemptively changing the bolts.

What do you think?
Thanks

The whole which VIN thing is not super clear and it has changed at least once, so I would definitely recommend that anyone who lives where road salt is used check them on a minimum of a yearly basis.

[Bigs]

The whole which VIN thing is not super clear and it has changed at least once, so I would definitely recommend that anyone who lives where road salt is used check them on a minimum of a yearly basis.

That sounds like a reasonable plan,
thanks