Summary

• Studying a truck with 1,000,000 miles helped Toyota enhance elements for the 2022 mannequin.
• The extraordinary sturdiness of the driving force’s seat shocked the Toyota group.
• The resin mattress and V-6 engine upgrades displayed a give attention to sturdiness and effectivity.

In 2016, Toyota approached a buyer from Louisiana named Victor Sheppard with a proposition: they supplied to offer him a model new Toyota Tundra pick-up truck in change for his 2007 mannequin. Why, would you ask?

Well, it seems that the truck had over a million miles on the clock! To put the million miles into perspective, that is equal to driving across the planet 24 instances, and but, the truck was able to go for extra. The purpose of this initiative was to take that truck and see what labored so nicely to face up to so many miles, and what could be improved.

When the advertising and marketing people requested Mike Sweers, chief engineer for Toyota trucks, if he wished this truck that had carried out 1,000,000 miles, he was actually intrigued. That’s why, when Sheppard agreed to make the change, Mike led a group of engineers on the Toyota Motor North America Research & Development Center (TMNA & RD) to review Sheppard’s pick-up.

From the inside to the mattress and passing by the engine, the Toyota group completely analyzed the specimen to raised perceive it and utilized the required adjustments and classes discovered to the subsequent iteration, the 2022 Toyota Tundra.

In order to provide the most modern and correct data doable, the info used to compile this text was sourced from numerous producer web sites and different authoritative sources, together with Toyota and EPA.

The Inside Held Up Admirably, With Only Minor Upgrades Required

Just as Sheppard’s million-mile Tundra was no ordinary truck,Sheppard was no abnormal driver. At six ft six inches and weighing 425 kilos, he was constructed like an NFL lineman and used this truck to make deliveries for an oil firm, which led him to drive roughly 125,000 miles per yr.

Naturally, that piqued Sweers’ curiosity within the situation of the seats. This is the rationale why, as an alternative of specializing in the engine or transmission, they determined to start out by one thing relatively easier: the entrance seat.

Even After Heavy Usage, The Driver Seat Remained Virtually Flawless

As Toyota staff took the truck aside and went to examine Vic’s outdated seat, anticipating to seek out plenty of harm, they realized it was remarkably unbowed. Despite the extremely excessive use, not solely was the body unbent and the froth unworn, however the seat itself, according to the remainder of the truck, confirmed solely mild put on and tear, one thing superb contemplating the truth that Vic had virtually lived in that seat.

This discovering absolutely made them rethink the best way of designing and testing the vehicles, as a result of the reality is that real-life utilization can undoubtedly function a greater benchmark than any laboratory check.

The Seat’s Comfort Level Was Upgraded Through Material Swapping

While the seat body’s energy was adequate, it proved essential to make it lighter in an effort to improve consolation and longevity.

However, introducing higher-strength supplies requires warning to keep away from compromising sturdiness. Finding the correct stability between energy and adaptability was essential, making an allowance for not solely bodily dimensions but additionally the life-style of drivers like Vic.

Concerns Regarding Odometer Limits Were Addressed

Looking at Vic’s expertise, Mike Sweers realized that even small elements just like the solar visor matter. The put on and tear on it confirmed Toyota the challenges drivers face on lengthy journeys. Based on this, it was finally redesigned to extend its longevity and, by the way, to reinforce user-friendliness.

Additionally, the concern of odometer limits surfaced, highlighting some unexpected penalties when setting digital limits on mileage. Vic’s truck challenged typical expectations, prompting a reevaluation of the established requirements and the necessity for flexibility as some drivers go well beyond the same old mileage.

The Cargo Box Showed Visible Signs Of Wear From Years Of Hauling

The dialogue surrounding the truck’s mattress is a subject that has gotten lots of buzz with this truck, being maybe probably the most vital takeaway. Despite its million-mile journey, most elements regarded surprisingly first rate, aside from the mattress, which regarded prefer it had taken a beating.

Moreover, upon teardown, sure areas, significantly across the deck, had been recognized as locations the place weld energy wanted enchancment. Vic’s line of labor as a hotshot driver typically took him to grease rig websites, the place dropping heavy drill bits immediately into the mattress left noticeable marks. This highlighted the necessity for a mattress materials that might stand up to such abuse.

The Resin Bed Emerged As The Optimal Solution

To treatment this drawback, Sweers and his group launched what they referred to as a “resin bed” or, in engineering phrases, the deck. Now, why did they go for this selection?

The dialogue initially revolved across the selection of supplies. While aluminum offered corrosion resistance and weight financial savings, it lacked sturdiness. On the opposite hand, high-strength metal was sturdy however inclined to corrosion. So, which choice was extra appropriate?

This dilemma led to the concept of a composite deck, similar to what is used in the Tacoma. Despite being dearer, it was a success amongst Tacoma prospects, so it emerged as the most effective answer.

The composite deck offered a number of benefits, equivalent to:

• Being light-weight, corrosion-resistant, and straightforward to restore.
• It allowed for modern options, equivalent to molded-in pockets for two-by-fours, catering to the various wants of truck homeowners.
• The sloped design, wanted by the manufacturing course of, offered a simple cleanup, eliminating the effort of filth buildup alongside seams.

They Went As Far As Throwing A V-8 Engine To Guarantee Its Endurance

Toyota torture-tested the mattress earlier than approving it for manufacturing; they dropped rocks, cinder blocks and even a V-8 engine onto the again of the Tundra. With a payload capability of as much as 1,940 kilos, the composite mattress survived with no dent.

The resin mattress represented an enormous leap ahead as a result of it took care of the noticed shortcomings in conventional mattress supplies. Besides, its purpose was not solely at enhancing sturdiness but additionally to enhance performance and person expertise.

Despite The Minimal Modifications Needed, The V-8 Was Swapped Out For A V-6

The 4.7-liter V-8 engine took a couple of victory laps round factories in North America earlier than ending up in Ann Arbor, Michigan, the place it was initially designed.

The 2007 Tundra is without doubt one of the earliest fashions geared up with that actual engine. Despite the truth that its proprietor drove round 125,000 miles per yr, totaling 1,000,000 miles throughout his possession, the truck’s unique powertrain remained largely untouched, with solely minor repairs revamped time, equivalent to changing an alternator and a water pump.

Moreover, the transmission skilled a problem with the reverse at round 770,000 miles, however in any other case it additionally remained the identical. How typically are you able to say that about any automobile or truck?

Some Components Were Upsized To Withstand The Demands Of The Improved Torque Ratings

As defined by Mike in an interview carried out for Pickup Truck Plus SUV Talk, Toyota’s requirements are set by the Land Cruiser 70 sequence; they function a benchmark for all their vehicles globally.

As they transitioned the powertrain, together with the switch case, that they had to make sure that it might deal with elevated torque calls for, particularly for heavy-duty purposes. This required scaling up parts just like the switch case chain to accommodate larger torque outputs.

Previously, the switch case used an inch-and-a-half chain, which was upgraded to an inch-and-three-quarters chain to fulfill the calls for of the improved torque rankings. While this will likely seem to be a minor adjustment, it significantly impacts durability and reliability under heavy loads.

Additionally, gear ratios had been revised, transitioning from 4.30 to three.31 to optimize efficiency with out compromising sturdiness. Contrary to well-liked perception, gear ratios do not have an effect on sturdiness; as an alternative, it is the dimensions of the ring gear and its cooling capability that decide longevity.

Moving on to prop shafts, Sweers’ group adopted a strong design to face up to the elevated torque output. By utilizing bigger shafts and high-quality supplies, the chance of failures was minimized, particularly below heavy masses.

Ballistic Nylon Skid Plates, Another Remarkable Innovation

Another innovation value mentioning is the ballistic nylon skid plates, a light-weight and sturdy different to conventional metal plates.

Originally sourced from a army provider, they provide superior safety towards impacts and corrosion. Their flexibility permits them to soak up shocks with out denting, making certain lasting sturdiness even in harsh off-road situations.

Setting Aside Durability Improvements, The Engine Was Transitioned To A V-6 To Improve Fuel Economy

Not all of the enhancements that Toyota made to the third-generation Tundra had been associated to sturdiness. The firm additionally improved gasoline financial system by replacing the last-generation model’s V-8 with a V-6 that is both naturally aspirated, twin-turbocharged or part of a hybrid system, and it fitted the rear suspension system with coil springs to ship a extra snug journey on and off the pavement.

Although the 4.7-liter V-8 proved to be a dependable workhorse, its gasoline financial system left a lot to be desired, offering a paltry 15 MPG on the street and 17 MPG on the highway – when you’re fortunate, which may’t compete with the six-cylinder choices.

For Having Over 1 Million Miles, It Was Remarkably Well-Preserved

The most intriguing a part of the entire course of is that, when Toyota tore down the truck, they observed put on and tear, however not within the quantity of 1 million miles value.

“This is how I’d expect a Tundra with 100,000 miles on it to look, but this one has a million”, exclaimed Frank Di Maggio, the analyst on the Toyota Collaborative Benchmarking Center.

It’s exceptional {that a} truck used so ceaselessly and used because it was designed might present such little put on. The key to attaining this excessive mileage, in response to Vic, was performing month-to-month oil adjustments and common tune-ups. It might sound extreme, however the outcomes converse for themselves.