yeah i would agree that its not normal to have that, or to be expected, but if you dont take care of it, why would you expect it to just be fine, after spending so much time in bad conditions...i guess i just dont get how people are always shocked that a frame and other things can rust when you leave them in a wet, salty, temperature changing climate...

Hello Cfranck1. Is the area you photographed the main area of concern? I just noticed that the passenger side ONLY, between the cat converter and rear axle, is rusting from the inside out on mine. Almost paper thin in spots, but in front of that and behind that area is sound as sound can be. The driver's side is solid as can be also. I do take care of this vehicle and under carriage wash it several times per year. The rest os the vehicle is rust free except for 2 small rock chips and the rust has not progressed in three years. I have 250K and it is an excellent condition vehicle. Most people can not believe it is 14 years old and 250K because it is so well maintained. From what I have been reading and from talking to other people, it seems that 98 & 99's frames rust mostly on the passenger side middle. I do believe that it is a quality control issue on these vehicles. Just like the high number of repeat left rear wheel seal and bearing issues. Must have been a welding jig error and the left tubes are slightly off kilt binding the bearing. Have read about many 98 & 99's with this issue also. I asked this because I noticed from your pics that the pattern and location is the same as mine and others I have seen. I love this truck so much, that if I can find.....hopefully, a from from Colorado or another no salt state that hasn't rusted, I will buy it, sand blast it, spray it with POR, and undercoat it and go through the inside with undercoating and go through the painstaking task of transfering my engine, tranny, front clip, suspension and tub onto the newer frame. It would be a shame to shit-can this truck, since it is still newer looking otherwise, and mechanically sound...with exception of a now rusting rear differential. This truck is worth the task. It is also a shame that these frames are welded, then heat treated, or a much easier task would be to weld in the passenger fram rail, but unfortunately the frame will only crack away at the weld seams because of the heat treating. I do find it odd that these trucks do not otherwise rust with exception of the rear diff, and the passenger side frame rail, inside edge, and inside out.

Look at all the destruction it does to the roads and the bridges.


But if it just saves one life, then it was all worth it.

If you think Toyota's rust bad, the 98-04 Isuzu Rodeo/Honda Passport frame rot issue is pretty bad. Rear trackbar completely rots off the frame.


However, Isuzu did take responsibility and offered inspections and a possible buy back of the vehicle if it was bad enough.

A little preventative maintenance and pre-buy inspection goes a long way. Checking for rust before you buy and then Washing your truck bi-weekly or even weekly pays off in the long run.

You sir are a hero, for bravely thinking of the children at all costs. Here, take my property and freedom too, to help you in the fight to save lives!

seems like we're beating a dead horse here, so I'll just say........I like turtles.

My 2001 Toyota Tacoma was recalled a few years back and Toyota replaced the rusted out frame for free. Now my 2000 4Runner has the same problem, and Toyota is ignoring it. I understand that both vehicles use the SAME frame! I had the 4Runner in for an oil change a few months ago, and Toyota dealer never mentioned this potentially life-threatening condition. It wasn't until I tried to sell it that the potential buyer pointed it out to me. What is Toyota waiting for--a fatality! I have complained to NHTSA. Has anyone pursued legal action, a class action suit?

While the 3rd gen 4Runners and the 1st gen Tacomas share a common basic platform, the frames and (more importantly) the manufacturing details differed greatly.

I've copy/pasted an excerpt from a post I wrote on this thread about frame rust.

I see that you are from somewhere in New York. As in Wisconsin, the use of road salt is a fact of life. Just as with any vehicle subjected to salt, the frame of your 14 year old vehicle has rusted through. If it had been a Tacoma, the frame would have rusted through many years ago.

Sorry, but I have to disagree with you about this allegation.

I agree with the OP that it is a quality issue. If you go to a Toyota dealer, and look under a brand new 4runner, you will notice that EVERY frame weld is missing spots of coating and is already showing surface rust. I live in Oregon, where it never snows, and have owned my 2013 my 4runner for less then a year, and already have to go over every weld with rust bullet so things don't get worse, which shouldn't have to be done on a new vehicle...

Look at the rust on this 6 month old 4runner....



Rust on 6 month old 4Runner

Maybe it is just me, but no frame should look like that after 6 months, even with no maintenance...

I agree with you Whiplash. I believe that Toyota has been on a downhill slide since all the recall fiasco of the last couple of years.

Just to update; my 99 has been running great. However I recently discovered a cancer spot on the rocker panel. So far I have one quote for 400 to fix it. I am on the fence if I will buy another Toyota. Fluid Film is great stuff. worth every penny.

Just to set any record straight, my 4R came from Ma. I have taken great care of this vehicle. I still believe Toyota can do better.

Scott

I just found "hidden" rust rot on my frame. It's in the same place that many of these pictures are showing - next to the muffler on the passenger side. I went from loving this truck to kinda hating it. I have sunk a couple thousand dollars into this thing in the 3 months I've owned it. I've had it towed once when it mysteriously broke down, (thought it was a bad fuel pump but I got it home and gave it gas while trying to start it and it started after a little coaxing WTF!)

To all you that think this is a maintenance issue, just the fact that this rust is happening in the same place on the frames - should answer that question. My truck also has the dif leak from rust. Also, almost got the pink milkshake. Point is, all vehicles have their common weak spots, it just so happens that the three things I just mentioned are three MAJOR components of a vehicle that cost A LOT of money to fix. Is it also a coincidence that they all seem to have something to due with corrosion? I highly doubt it. It's a shame because I really like the truck. Drives great after fixing the things I fixed. I also believe the motor would run a long time with proper maintenance. I just wish I had the time to research this year truck before I bought it. I was under the gun, without a vehicle after a total loss on my previous vehicle. I would have ruled out the 4runner unless it came from a warmer climate. I truly envy you that don't live in the "rust belt"

Sorry for the rant but I am just really mad about this. Really disappointed. I enjoy reading this forum. You guys know and love your 4runners. Believe it or not I like working on the 4runner. It's somewhat easy and there's a plethora of parts available ,new and used. Don't take this wrong, but I'm not a vehicle "fanboy" Ijust want a good reliable vehicle that I can maintain and not have to worry about.

After reading this thread, I don't expect much sympathy. There's a lot of 4runner love here and rightfully so, and expected, as it is a 4runner forum. I guess I just expected more from a Toyota, and, to be honest, expected problems because I bought used, but this is ridiculous! If I owned this truck from the beginning I may have caught this, maybe. I've had MANY vehicles here in NJ and I've never seen anything like this before. My '92 Exploder had the rocker panels rusted out and the frame was just beginning to rust but that truck was almost 18 years old when I sold it. Still going to this day. (my brother in law bought it) I will try to fix this. I have to. I know some welders. Gonna fix it right (if a frame can be fixed right) then probably sell it as I just don't have a good feeling anymore about it. Shame because other than these things it's in great condition and, from what I've read, a very desirable year and package. Flame away.

I will say one thing. My '96 had pretty bad rust hole in the normal spot, back side by the muffler, etc. When I got hit (Dodge pickup), going at least 40, right on my passenger side wheel. The frame nor the control arm mount budged. Destroyed the body and what not. I really think the main outside C channel frame carries most of the load. I'm no engineer, nor do I care. I was just really surprised that as much as I was worried about that frame and bracket, it was a bit stronger than I thought. That said, I'm not normally one to tempt fate.

Im in Northern Ontario and they use a shit load of salt and sand..I just rebuilt the frt floors and it was"t pretty..I have under coated every other year with corroision free. The rust still finds it"s way to the frame. I have to go underneath and beat the frame with a hammer and scrape whats there off the layered cake of crap. That will be done this week...I find that it should be done every 3-4 years...the only way to beat it is move where there is no snow..

What is the "main outside C channel"?