This is going to be an on going thread that will not be associated with my build thread. I'm going to be fixing all the rust issues on my 01, and will most likely not be a fun process.

The plan is to start in the front, and work my way to the back. I'm going to tackle this in 3 sections to help save my pocket. I'll try to detail this as much as I can with part numbers, and pictures.

*Most of the links below are just for reference, and not what I'm actually buying.

Step 1: Front bumper to front door

• OEM UCA's (48610-35040)(stock shaved UCA's)(PURCHASED)
• OEM UCA Bushings (48632-35080)(PURCHASED)
• OEM LCA's w/bushings (used LCA's from eBay)(PURCHASED)
• LCA Bushings (Whiteline W53377A)(PURCHASED)
• LBJ's (OEM 43330-39585) (PURCHASED)
• Calipers - (OEM 47730-35110)(PURCHASED)
• Braided front brake lines - (PURCHASED)
• Cam mount bolts (OEM 90080-11283)(PURCHASED)
• Cam sub-assy - (OEM 48409-35050)(PURCHASED)
• Cam adjuster - (OEM 48452-35020)(PURCHASED)
• Inner TRE's (OEM 45503-39075) (PURCHASED)
• Outter TRE's (OEM left 45047-39215, OEM right 45046-39335) (PURCHASED)
• CV's (NAPA)(PURCHASED)
• Sway bar bushings & bump stop - (PURCHASED)
• Rotor and Pads- Summit Racing(PURCHASED)
• Caliper Bolts- OEM 90105-12175 (PURCHASED)
• Anti-Rattle Spring- OEM 47748-60030 (PURCHASED)
• Shim Kit & Anti Squeal- OEM 04945-35040 (PURCHASED)
• Brake Line Clip- OEM 90468-08046 (PURCHASED)

Step 2: Front door to rear door

• Frame repair with 1/8" plate
• Cross member mount front (OEM Left 51026-35020, Right 51025-35020)
• Cross member front (OEM 51203-35321)(PURCHASED)
• Cross member mount rear (OEM Left 51028-35010, Right 51027-35010)

Step 3: Rear door to rear bumper

• LCA mounts (OEM Left 51504-35010, Right 51503-35020)
• E-locker rear axle (CL find $100)
• E-locker 3rd member, wiring, computer, and switch
• Frame repair with 1/8" plate

I'm also going to be doing some body repair due to rust issues.
This is going to be a work in progress, and I should be getting started on this next month.

Sub'd! I'll be doing the same thing to my 01. Do you have any places on your frame that are rusted though? I gotta spot in front of the rear axle that ain't to bad right now but wanna get it taken care of asap

How bad is is? :

Just the inside of the frame about the size of a quarter.

I did a repair last year on the passenger side. In between the rear LCA mount, and the cross member around the rear door.

I'm going to cut that section back out to make it look nicer. I'm also going to cut off the LCA mount since I had to patch over that section. I think I'll end up cutting our most of the passenger side frame from the LCA mount up to the front cross member around the front door. About a good 48" section just to make sure that I've got it taken care of. From what I can tell the driver side seems to be in good shape. I might do the same thing on the driver side as well though. Just for that piece of mind.

If it weren't bad I wouldn't be going through all of this. This task isn't going to be hard, just time consuming. On a side note the wife is letting me get a plasma cutter to make it easier.

That's how mine started, and I stressed started. I took a mason's hammer to the frame, and lightly started tapping that area. The rusted area kept getting larger until I went from about a 2" to an 18" section.

Yeah My rot is on the passenger side right before the rear axle. I just got my runner this past weekend and found it while I was taking the running boards off. I was expecting it though cause it was from NJ and I actually thought it was gonna be worse

How's your rear axle housing look? I was in the process of taking care of my rust when my 2000 got rear ended and totaled. I totally lucked out on a 1999 with MUCH less rust. Found it in NJ too. What a difference it is to work on.

I got some of those crossmembers from Death Cougar, specifically the one under the Trans. The one he sent me looked brand new.

Your right about the rust being extensive once you get into it. Whenever I read on here that people only have "small" rust hole in their frame or it doesn't look that bad yet I cringe because I know the inside of the frame is A LOT worse.

RUST SUCKS!!!!!!

i know it's not small by any means, but I've been putting it off.

The rear axle isn't leaking, but I also don't feel like messing around with it. I picked up an e-locker housing for $100 that's in good shape. I'm plan on picking up a 3rd member with all the goodies for it. I'm basically going to build up a new rear axle with the exception of a few things.

I'm leaving in a couple years for a massive road trip, and I'm hoping to have this thing is great shape by then. Plus I think we're getting a 4th or 5th Gen to go along with the 3rd. I don't want to have the 5th Gen payments, but the MPG are so much better than the 4th's.

My plan is to just keep cutting until I find good metal to weld to. I'm glad the runners have a boxed frame. It would kill me if this would happen to my taco that's why I keep a good check on the frame

I'm sure it's bad but exactly HOW bad haha I want to compare our amounts of rust. Mine is pretty bad considering I had to get a new rear axle 4 months ago because the mounting bracket rusted off.

My axle is just rusted, but not fallen apart. My frame is where the damage is. I'm going to cut things off that don't need to be cut off, and this is because I want to eliminate potential rust under/behind those brackets. I'll get some pictures posted up.

Most of mine is on the frame too, none on the axle anymore. It's so bad I'm considering just driving this one long as possible until the frame gets to the point where I can't and then getting a different 3rd gen. I don't feel like a frame swap or extensive cut and weld Could fix it.

You couldn't pay me to do a frame swap. I'd rather get a new 4runner than go through that.

That's exactly how I feel. Especially since I don't have an actual "garage" with 1000s of tools. With our frames as susceptible to rust as they are I'd love to find a rust free frame and por-15 the living crap out of the whole thing and then do a frame swap, but it's just an insane amount of work. I'd get all that done and then everything else other than the frame would rust out because everything underneath a 3rd gen can and will get rusty haha.

still learning lots about these Toyota 4runners, but you guys talk of rust issues, and the tacomas have a frame recall ....does this not apply to rusty frames of 4 runners ?