First time poster here. Have a 2000 4 runner 3.4L V6 4wd with 170,000 miles. Noticed today that the passenger side longitudinal frame rail (running front to back) is perforated for about 24 inches along the inside bottom of the rail running beside the muffler, back to and including the point where the lower suspension arm attaches to the frame. Structural integrity of the inside of the rail compromised where perforated but the bottom/outside seem in good shape. I have seem some discussions on Tacoma's on frame rust and I think they recalled some of them. I did an unsuccessful forum search here but likely wasn't looking in the right place (sorry). So - how bad is this? What is the fix? Can it be welded and how big of a job is it? I have had this car since birth (the 4Runners, not mine) and intended to make it last to 300,000 miles - it runs great! The corrosion caught me by surprise.....

thx,

John

I feel that it will catch alot of people by surprise. I have heard numerous reports, including having perforations in that area myself. It is not a very visible location, so people don't often look for it. I had a patch of steel welded over the perforations for 140 from a local welder. You may want to do just that. I also recently repainted most of my frame and rear axle. This also included using some Eastwood internal frame coating along the inside of the frame.

Good info - what did you have to do get it ready for welding (i.e. pull gas tank, etc.)? Was it just bar stock that they welded over the inside of the rail or something more sophisticated?

Do you have any thoughts on what the urgency is to fix this? Can it wait until I drive it 3,000 miles to Maine and back?

As I get older, I don't crawl under the car as often (or as far) as I used to. Yes, you have to get under there and take a good look to see it......

thx,

John

i had mine rust on bothe sides one side i had to drop the gas tank to fix all i did was go over it with a peice of flat stock and welded it to it and havent had any problems since then

Oh, here we go again... LOT's of threads on this issue, keep searching. Also, check out the link in my sig, I have linked some good threads about frame rust in post #29. I bet your rust isn't as bad as some people's we have seen.

Post some pics of your frame, it helps us gauge the severity of your problem.

x2 for pics....

Saw that you were correct about many threads on this topic. My rust looks just like PSUArcher's rust in post #8 in the following thread:

Serious Frame Rust Questoin

Exact same place and appearance.......I would like to see some "post-repair" pics of rust in this location and get some specifics on how the welding was done. I will do some grazing through the forum but if you know off hand where I can find them, I would appreciate it. I think I will also call Toyota about it but, based on all the discussion, expect they will be unwilling to help. Plan to get it welded and use some of the Eastman internal frame coating on it......talked to a buddy that had his Tacoma "fixed" per the recall. They coated the rust with what sounded like the Eastman product and called it done. They didn't do any welding or replacement...

thx,

John

Well, if you look further down that thread, you will see the welding job that Wallace had done. That is the only welding job I can remember being posted here. you might find others elsewhere, but I havn't found them.

AS far as the specifics on the welding, you should just talk to the shop you take it to about how they suggest doing it. A good welder should be able to do this no problem, just make sure they are a good welder.

Thank you. I did see Wallace's pics....I will talk to the shop but having some preliminary thoughts about how it might be done puts me in a position to have a more constructive conversation (and lets me better evaluate if they know what they are doing). So, if others have experience with the fix, let me know.

Also, called the Toyota Customer Experience Center (that's quite a euphemism - some PR person got paid big bucks to think that one up), spoke to a very nice young man and lodged a complaint indicating that this was a safety issue. They indicated that they do not have an ongoing program to address this issue (as expected). Made a complaint through the NHTSA web site which is a very easy process, by the way.

Thanks for the comments to date.

thx,

John

FYI - I did have the frame welded - flat stock welded on the inside of the rail from the bracket of the lower control arm up to the frame cross-member. Also had flat stock welded on both sides of the bracket - nice job. Had to remove the muffler so that the work could be done. Cost me $400 plus tax. Had it done at Farris Frame Restoration in Pataskala, OH (near Columbus) and recommend them. They get a lot of work from out of state as well.

After looking at this closer, I think the lower control arm bracket was the primary safety concern. It was perforated completely on the in-board side and starting to be eaten up from the inside-out on the out-board side.

Appreciate the input.

thx,

John

Nice, sounds like a pretty good deal... But you know you can't post that update and not post pics. So here it is...

Buckaroo...

Thank you so much for identifying and endorsing Farris Frame Restoration in Pataskala, OH.

I discovered frame rust issues yesterday and after searching for a repair source locally in Cleveland for 3 hours to no avail... I found your post...

I now have a course of action thanks to you!

Hi all - just in the past month discovered my frame rot which extends near the back right wheel. Took the car in for a 4WD issue and the auto guys discovered the rust and promptly told me the car was unsafe to drive. Glad I found this out from them and not by having an accident.

I was told by someone that my 4WD issues (basically not engaging in 4WD) may be related to the rust. They said the frame rot may be warping the frame to the extent that the gears involved in the 4WD are messed up. Anyone else have an opinion on this?

I brought the car to a dealer and they refused to look at it and told me to call customer service. Called customer service and they told me the frame issue is not related to the Tacoma issue because the Tacoma frames were made in the USA while the 4Runner frames were made in Japan. Doesn't mean they weren't using the same materials or process, right? Maybe?

Anyway, here's to hoping that as more people discover the issue and file complaints that Toyota will take action.

Everyone that owns a 4runner should contact NHTSA and the FTA and file a frame rust complaint. Toyota has recalls for this problem on the Tacoma, tundra and sequoia, but 4runner owners are being screwed. you can file a complaint on line it only takes a minute.

Translation: I didn't take proper care of my 4Runner, and wash off salt as spelled out in the owners manual. Now I'm looking for someone to blame because of my own negligence..


The Tacoma, Tundra, and Sequoia frames were improperly made by Dana Corp. They are much more susceptible to rust.

4Runners have always been made in Japan. The frames are much more corrosion resistant. Of course when neglected by owners that didn't read their owners manual, or that apparently lack common sense, they can rust away given enough time and neglect, too.

My 4Runner has spent it's entire life in a State that heavily salts the roads, all winter long. If I had neglected to clean my 4Runner as needed (sometimes several times a week) during all those salt-encrusted Winter's, it would have rusted away long ago. As it is, it is in great shape, because I put in the effort to keep it that way.