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Horrible Grill Design = Hole in AC Condenser $600 Ouch

7.8K views 37 replies 29 participants last post by  blackgts2002  
#1 ·
Evidently a rock or some other highway debris flew up and poked a hole in my AC condenser. No more AC for me. Upon close inspection it's not hard to understand why this would happen. The open channels in the grill are just too big. Now I need to research a new grill or rig some sort of chicken wire protection, because this is bound to happen again especially on gravel roads etc. In the meantime my dealer informs me that it's just bad luck and it's only going to cost me $600 to replace the condenser. I understand why it's not covered by warranty but this grill design is horrible. Be warned, protect yourself or be out $600 bucks.

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#3 ·
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I often thought of getting a "fine mesh S/S billet grill" for this reason .. to stop rocks. .. :eek:

Now, I will install a fine mesh - 1/8" galvanized welded wire aka "rat wire" .. paint it black and install it someway behind the grill.

Thanks for the "heads up" on this issue. .. :D

SOS
.
 
#4 ·
FYI, I bet you could find a local place to repair it, then get it recharged...
I use this place for my dirtbikes...Mylers Aluminum Radiator Repair
There has to be a place to do what you need.

Hasn't failed me yet.
 
#10 ·
State farm wont hold anything against you if its under $750 pay out.
Still not really worth the trouble, maybe if you have a $250 deductible.

The grill is sure wide open, I think a popular mod will be, 1/4 inch mesh.
Sucks, I would be furious, do you know how much for just the parts, maybe a local shop can do it cheaper (with OEM parts) than the dealer.
 
#11 ·
I bet most people have a $500 deductible, meaning the $100 claim is not worth the effort to file the claim.
Actually, no they don't. One aspect of my job is as a finance manager and I have to tell the banks what deductible levels the customers carry. The bulk of my customers have either $100 or $250. I haven't taken a scientific survey though.


You are right that if you have a $500 deductible, it wouldn't make sense to file a claim for a $600 repair.
 
#12 ·
my trans cooler has a nice ding in it from a rock. I found it when the truck had about 800 miles on it. I agree with most that the Tundra grill is not very effective against marble sized rocks or debris. Baseball sized maybe but even that is a stretch.
 
#15 ·
Buy the condenser and drier over the counter (try for 15-20% off list) and install yourself. Add approx 1.5 oz oil for condenser and about the same for drier and have someone lined up to vacuum down and recharge.

Add some .25 or .125 screening between grille and condenser/aux trans cooler.
 
#17 ·
Wow, seems like alot of automakers are enlarging the holes for the radiator. Had the same issue with my other cars and installed grilles on all of them except my truck.
I went to the accord forums when I bought my 03 coupe and someone there had the same thing happen to them. The following week I installed a mesh grille off ebay.
In 06, bought an Element and went to the element forum and what do you know. That same day ordered a billet grille and installed the following week.
Now it's 07 and on the Tundra forum.... going to check ebay for some grilles :p.
The only car I didn't install a grille on was my G35 coupe and wifes VW beetle. There was no way for a bug to get sucked into one of those, let alone a rock.
 
#19 ·
Here's what I did after seeing that my brother's Tundra already had a large ding in the condensor...probably from a rock.

I went to Lowe's and picked up a roll of the fine mesh screen made for pets. It looks like regular window screen except it has a black fiberglass coating and is more flexible than wire mesh. I cut it to fit the rear of the grill and used the existing 10mm nut washers to fasten it to the top and sides of the grill. For the lower part, you'll see little flat head screws which I used to fasten the screen to the bottom part of the grill.

It is holding up well and since its black already, you can't even see it unless you get up close to the grill.
 
#20 ·
$600 is ouch alright! :(

I agree with others consensus first. Try to find a repair shop to straighten that out first, or at least see how much they would charge. If it saves you money and works in the end, that's the important part! :tu:
 
#21 ·
I have the cloud rider stainless grill on my Tundra.It stops the rocks and the majority of the bugs as well.
Can you post up some pics of this grill? I'm in the market and have not yet seen what I want. thanks
 
#22 ·
This setup isn't uncommon. I had this happen to my F150. The shop wanted 800 bucks to repair it. I said no way given I only use it a few times a year. (Mostly ride Mcycles in the summer).
The fix for me was an air conditioner sealer sold at NAPA. This is not the common 134 with sealer but a smaller can with just sealer. It was about 35 bucks. But it lasted 4 years and the AC still worked when I sold the truck.
 
#24 ·
This same thing happened to my neighbor only a few weeks after he bought his 07 Crew Max. He was really pissed, but I think somehow he got the damage warrantied.

I hope I don't run in to this. I was thinking about a Billet grill but I am wondering if air flow is a concern ? Will the air flow be the same thru the billet as thru the factory grill ?
 
#25 ·
Now, I will install a fine mesh - 1/8" galvanized welded wire aka "rat wire" .. paint it black and install it someway behind the grill.
Let us know how you install it, maybe with some pics ???
Clearly a concern for those of us who travel rocky roads....