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01rangerXL, You just do not get it! The age of a design has nothing to do with it's durability. If you look at the Tacoma for example all of the drivetrain is basicly a continueing evolution of the HILUX pick. So their is not really anything new to the axles,transmission,transfere case just slight changes and improvements. The interior is probably the best it has ever been in the Taco right now. The chasis and sheet metal componets have continued to improve in terms of materials and design. The computers software used in conjunction with newer types of steels allowed the chasis to be made more stiff and torsional rigid then the previous HILUX model along with a 500lbs. weight saveings! You just can not do that type of thing with a 13+++ year old design. Toyota's axles design is the best on any small pickup and has been since day one. THeir transmission automatic or manual tend to last the life of the truck or at least as long as the engine! Look at the I4's that are available in the two wheel drive Tacoma's! A lot of the Rangers that we had at AutoZone had transmission problemes.
The Colorado and Canyon are really nice trucks as well. I will admit I am biased toward the Tacoma but if I could not afford a Tacoma the GM compact pickups would be my next choice. I test drove them as part of captured fleet and they are nice in terms of fit,finish,NVH etc....The only think I wish they would have done differntly was kept the 4.3 as an optional engine and given it a 5 speed automatic instead of the old and outdated 4L60E. An additional gear and some newer shift algorythms would have made they available engines much more dynamic in my opion!
The age of a design does have an important role with durability. When a design is proven over years of use, it is generally a safe bet. With a new design you are taking a bigger gamble. That does not mean that the new design will not hold up, but you are not taking a gamble with the proven design. The original poster said he wanted durability. The Ranger has been PROVEN to be a durable truck through decades of use.
Do you have some evidence to show that Toyota's axles are better? Even the small 7.5" axle on Rangers seems to hold up well if you do not swap in a V8 or put on huge tires. The 8.8" axle on 4.0L and most 4WD Rangers is practically bulletproof and can handle big tires and high HP motors.
The M5OD transmission in the Ranger is durable as well. It will last as long as the truck as long as it does not get filled with gear oil. The original A4LD OD automatic was not known for stellar reliability, but later variations of it (4R44E, 4R55E, 5R44E, and 5R55E) have significant improvements made and can last as long as the truck if cared for. Not sure what kinds of reliability problems you have experienced, but I know the 5R44E in my parents truck shifts flawlessly and always has since day one.
Just because the 4.0L is available in the Hilux (in a very small number of markets) too does not mean it is proven. It is still a fairly new engine. The 2.7L has been around a while, but I am not sure what its reliability track record is like. Most Hilux trucks get diesel engines.
Also, be careful comparing the Hilux frame to the Tacoma frame. They are no longer built on the same platform. They are not twins anymore. Really, any comparison between the current Tacoma and Hilux is not really valid unless you are talking about an identical part.
I will agree that the interior of the new Tacoma is much better than the one in the previous generation. 2004 and older trucks were cramped and it resulted in questionable crash test results. New trucks are greatly improved. Ford still does offer many more material and feature choices though. You are stuck with cloth and carpet in a Tacoma.
As far as fit and finish, NVH, etc... The Ranger has been beating the Tacoma in JD Power initial quality surveys since the 2005 redesign of the Tacoma. I think that is something worth noting.
The Ranger is an oudated truck in need of a redesign, but that does not mean that it should not be considered. For a lot of people out there it is still the best truck for their needs. Just because the Tacoma is newer, more expensive, etc... does not mean that it is always going to be the better choice for every person.