Toyota HiLux 2004 Problems

The Holden is cheaper because more people are choosing the Ford. If it's close enough on features, and ahead on value, then park the dream for some reality. But perhaps also cross-shop the Mazda BT-50, which is a clone of the Ranger.

There's no problem in using fifth gear on the flat, but you also have to be aware of the terrain and change down when facing an incline. Leaving it in fifth will stress the gearbox and could lead to the sort of failure you have experienced.

HAVE you thought about repairing the chassis? Cracking is not necessarily the end of the world. I'd check with a chassis specialist who can inspect the cracking and determine if it's worth repairing. If you are intent on fitting the body to another vehicle it comes down to the weight of the camper body. Think about the weight when it's fully laden with all the gear you plan to take with you. The vehicles you're thinking of are nominally one-tonne utes, so they should do the job providing your camper is one tonne or less when full of gear.

The Hilux is tempting because of its reputation for toughness and reliability; there are no particular years to avoid. The most important thing is to buy on condition, look for one that hasn’t been beaten up. Do that and you should be ok. You could also consider a Mazda BT-50 or a Mitsubishi Triton.

WITHOUT knowing what you do with your cars and how you drive them, it's hard to comment. But if you drive them normally, I would think you do have a claim against Toyota. Having to replace a gearbox at 40,000km, and even at 80,000km, is unacceptable under normal use.