Crazy story about how my v6 failed at 78,000

Long time Toyota truck guy but first time posting here. The engine on my 2017 Taco with 78K miles started running really rough - brought it in and they found zero compression in cylinder 3. Mechanic removed the head and found an extra rocker arm (all twelve of the others were in place) had been left in the engine and was holding the #3 intake valve open. I had the mechanic repeat that because it sounded so bizarre.

The truck was purchased new, no major work had ever been done on it - so it left the factory with this extra rocker arm rattling around somewhere and took 8 years and 78,000 miles for it to get into a position to cause a problem.

The bill to remove and replace heads, remove the extra part that was left in the factory and repair the damage it caused ended up costing $5655. I was over the powertrain warranty, but reached out to Toyota corporate to explain the situation - hoping they would at least cover part of the repair since it was obviously negligence on their part to let an engine leave the factory like that. Phone calls and email gave the same response from Toyota corporate: Sorry - you're past warranty.
Disappointed but not unexpected. I was surprised, though, that they had no interest in seeing the part or reading the mechanics documentation. It seems there is a fundamental flaw in the engine manufacturing process and Toyota has no interest in determining how it happened or taking steps to ensure it doesn't happen again.

So personally, the Toyota rep for quality and reliability is no longer. I get it, things can happen - but for corporate to stonewall and not even attempt to figure out how it happened has scared me off Toyota for good.

 

They have no interest in it because you're quite probably one 1 in a million.
It sucks, no doubt, but even if true, they're not going after a 1 in a million problem.

 

That’s insane. I’d try again to escalate that up the Toyota chain of command. Maybe futile but I’ve got extra time these days I don’t think I could let it go

 

That is crazy.

To be honest, powertrain warranties are too short. 100k / 10yrs changed the landscape for Hyundai / Kia and am surprised that Ram is jumping in only now.

In general, I agree with what you were told as an official response, but Toyota should have jumped in with some good will. They are definitely slipping with customer satisfaction.

 

I agree
I would go all the way to the top with that one . That was someone who went on a lunch break or got distracted and left that there

 

Wow! you need to buy a lotto ticket! Sucks that it happened to you but what are the chances? Anyhow shit happens.

 

Damn, one more thing for me to add to my Taco worry list!

 

Welcome to the forum

Talk about a notable first post.


I spent my working years in manufacturing, when you are making thousands or millions of parts a year things will happen -- even the best carpenter bends the occasional nail you could say.

It could have been anything from a machine malfunction to an employee who just had words with their supervisor, if I was a betting man experience says my money goes on the employee.

As far as "a fundamental flaw & figuring it out" without access to a time machine going back 8 years they really don't have much to work with.

Sorry you couldn't get a goodwill credit on the repair however it is understandable from the company point of view, the truck gave you good service beyond the warranty.

Also from the company point of view, you are a name with a VIN number, a rocker arm and an unusual story looking for $5,000 - it is sad to say there are a lot of scammers out there.

I'm not saying you are one of them but we all get them on our phones, e-mails, in the mail - things are different today sadly.

 

Also, how did the repair Go? Does it run good now? I agree with others, you may have to push to get some compensation. I think some good will is defiantly appropriate here.

 

Precovid build at that I guess when there isn't any part shortages sometimes you get an extra part. They can't even give you a rebuilt engine at their cost? You might even trade that rebuilt engine truck in on a new one. With that kind of luck I wouldn't trade it in on a new Tundra, maybe all those engine replacements won't allow Toyota to do any goodwill for the rest of their customers they still have a bottom line. No offense Tundra folks I've been picking on the Tundra this week, hell it probably drives better than any other half ton you can buy today.

Edit

I guess you don't even need a rebuilt engine as yours was repaired.

 

I may be one of a few. But wasted time.
That’s all you’re going to get by “escalating” anything.

If you want to fight something, fight the cost of doing both heads. Why both?

That’s the only thing I see worth fighting for. (If at all)

And argument can be made that doing both heads make for better work. But it’s not 100% necessary. And no way the dealership would have done both if this happens under warranty.

 

Why didn't the mechanic just take the extra rocker out and button up the valve cover? Sounds like a lot of extra work happened that wasn't necessary

 

I'll bet with some effort you'll get Toyota to stand behind this. You have in your favor that (1) you're the original owner, and (2) it was discovered by a Toyota dealer.

 

you might explain this to toyota. you may have to decide if pursuing is worth $5000. you will likely get attorneys fees when you win, but small claims might be first step. if they insist real trial, you will need attorney.
based on what you posted, guaranteed they will settle once a toyota attorney sees it.

partially quoting perplexity.ai answer:

Warranty vs. Negligence

• The expiration of a warranty only limits your ability to get free repairs or replacements from the manufacturer under the warranty terms. It does not shield negligent parties from liability if their actions (or inactions) caused harm or damage68.
  
  
• If the defect is due to a manufacturing error and not maintenance, you may still have recourse under product liability laws, even after the warranty expires, depending on state law and the circumstances.

 

You might consider a lawyering up and having them write a demand letter for a meeting on this, because you were deprived of your goal of reaching 400,000 miles. Something that others have been able to achieve. You'd be surprised, a simple letter from attorney might solve the whole issue. It's worth a shot! That's a lot of money. Good luck and thanks for posting!

 

Thanks for the replies. Yes, part of me wants to keep pushing for resolution but so many calls and emails getting the same canned corporate response, you just run out of bandwidth in your life to keep at it.

Also, point taken, I'm just another VIN with a pretty implausible story as far as Toyota is concerned. I'm surprised they wouldn't want to see the rocker arm. It's tumbled around like it spent 8 years in a rock tumbler but with none of the ordinary wear pattern you'd see in a rocker arm.

Hell, if I was trying to scam them I would've come up with something more believable than this. Anyway I'll keep you posted. If anyone has contact info for someone that might actually care, I'd appreciate it

 

You should mail that to Mike Sweers, along with your letter. Tell him what happened and that we're all patiently waiting for a reply. Shoot, now you've got me concerned about my truck...

 

@GTGallop had an interesting interaction with Toyota corporate here. You might want to PM him for some advice.

 

I will say Toyota of today is not the same as Toyota of 40 years ago. I had an 86 MR2 and the temp gauge quit working 3K miles out of warranty. Toyota back then covered the repair.

I did not even have to ask. The service writer contacted Toyota Corp. and they said the repair is no charge.

 

i would ask the dealer for an address to contact toyota for disputes and make it clear it is negligence. keep escalating until they give up.
the mistake, and the out for phone answerers, was referring to warranty. it is not that kind of case based on what you posted.
definitely hold onto the spare rocker but your ace is the report from the dealer.