OEX has a few. they said theres hardly a part that swaps anywhere. having crawled around one, it definitely isnt the same truck as a tacoma.
the hilux has basically the same design parameters as the 7x in capasity and footprint, but with IFS. considering the size of the trucks, you go bigger than 33's on either and youre into wheel spacers for turning radius. assuming the truck is for long distance travel, and not recreational wheeling, that limits you to 33's and minimal lift. i would say that "overlanders" would likely add lockers if not already present.
once you factor those items in, you realize a live front axle doesnt bring any advantages to the table over the IFS, and the IFS makes washboard tolerable, and allows for a wider range of long stroke straight 4's and 6's to be designed in from the factory. (oil pan)
i wouldnt be surprised if toyota offers a few more body styles in the hilux, when it kills the dinosaur. the chassis is light years better than a 7x. i like the box look of the 7x too, but if someone offered me a cab/chassis in either to use free for 100,000 miles of travel, id kick that 7x to the curb.
Only partially correct based on the research I have done between the two. Parts are not the 'same' in that they can't be swapped between rigs due to slight variation in options, mounts, etc.....but are fundamentally/internally identical, such as:
1) Front axle/diff - same
2) Rear axle/diff - same
3) Transfer case - although manual vs electronic
4) R&P Steering - same
5) Engines - 4.0 and 2.7 are both reasonable popular around the world, many markets get these in Hilux's. With that said, the 4.0 is popular in the landcruisers also.
6) Transmission for the above mentioned engines....still have not concluded if the auto and 5-speed manual are the same as the D4D. I'd suspect they are fundamentally the same with minor ratio variations.
Areas where things differ:
1) Frame - boxed vs channel
2) Brakes
3) Interior
4) Exterior
5) TCase - same internals, different operation
6) D4D
In my mind they are fundamentally the same vehicle. I was always of the opinion that the difference in GVW/Payload was primarily due to the US Market wanting a smoother ride and needing less capacity, so the spring rates vary and the frame is designed with more flex. I don't believe the Tacoma to be built 'less' rugged per se.
Regarding parts being welded vs bolted on the Hilux vs Tacoma - it's a great point and valid if your living in Afghanistan but wouldn't call it a win for the Hilux but rather a reasonable way of mitigating risk associated with lack of maintenance by Toyota.
Somebody posted that you don't hear about broken diffs in Hilux's, not surprising since only in the US do we slap mega tires on our rigs. Remember, many countries have STRICT laws concerning lifts and tire sizes. I'd imagine 99% of Hiluxes around the world being used 'offroad' use 235/85/16's as a max. On the extreme end of the spectrum you have Arctic Trucks with 38's, but their latest creation used a Tacoma as a base platform, go figure...