KUN Auto Gearbox failure due to underpowered diesel turbo

[Australogyra zelli]

Hi All,

My KUN 2007 Hilux diesel D4D turbo auto trans dual cab has had a GEM recond engine fitted then gearbox failed after 20,000km (185on dial) - engine is much lower in performance than original and gearbox fitters will not warranty new auto box unless engine fixed (Dyno shows it 10-15% down on similar vehicle). Anyone heard of any of this?

Thanks,

Len

:-)

[Manxman]

What failed, and why? NB new seals at front and rear of tranny should have been mandatory. Were you trying to hurry it to make up for poor performance? What is servicing history for tranny? Most unusual to wear out a motor so soon--harsh driving &/or poor maintenance suspected. Automatic failure similar-trannys normally give long life if serviced properly. Rare for a Tojo to fail so soon without very good reason.

Edit#1

Sorry, 07 D4D -- these motors have a design fault where the injector seals fail early, and if not changed often, their engine oil carbonizes and the carbon blocks the oil pickup. Affects 05-07 motors AFAIK. Doesn't explain tranny, tho'.

Edited October 1, 2015 by Manxman

[trentmeyer23]

Could very well be the injectors starting to die.

[Australogyra zelli]

Thanks folks. The engine died I presume due to the injector issue - wasn't diagnosed in death at 160,000! The new GEM motor is way down in power (20,000km and 10-15% less on Dyno) and has lockin problems with torque converter which Auto Trans Man says is due to low engine power and therefore won't warranty it unless engine fixed. It's with GEM re-fitters at present. Some say the EGR valve has effect on box but can't link the power issue? Thanks. Len :-)

[Australogyra zelli]

P.S. The engine was maintained as to the book and the tranny had only been serviced last year. :-)