[Chickenlords]

2004 4Runner Limited V6 with 205k miles from Iowa. Apparently neglected to do a thorough evaluation of the frame at any point in the last 5 years that we've owned the vehicle.

Got under it yesterday to replace a rusted through gas tank strap. Heard lots of frame creaking and while using a floor jack and upon further evaluation found 4-5 spots where a screwdriver could easily penetrate rust on the frame (mostly near welds) and another on the passenger side rear wheel connections. If i had to estimate. There are at least 3 spots where the rust is 1/2 through the square frame. Meaning, the total bottom and side are basically just flake rust.

Aside from frame replacement, I am assuming this is fatal. Can anyone confirm? Picture below.

If so, I may see what I can get on trade. Alternatively, could part it out as there isn't anything else wrong with it.

So sad. Wanted this thing to go to 300k+

[2003V8LTD]

I'm not totally sure that's fatal. There are a couple of companies that sell weld-on frame reinforcements for a 4Runner. I believe one is called SafeTCap or something like that. I wouldn't give up on it until I have priced out a reasonable repair, because an '04 Limited is a really good thing and would probably last many more years if you get that fixed properly.

Originally Posted by Chickenlords

2004 4Runner Limited V6 with 205k miles from Iowa. Apparently neglected to do a thorough evaluation of the frame at any point in the last 5 years that we've owned the vehicle.

Got under it yesterday to replace a rusted through gas tank strap. Heard lots of frame creaking and while using a floor jack and upon further evaluation found 4-5 spots where a screwdriver could easily penetrate rust on the frame (mostly near welds) and another on the passenger side rear wheel connections. If i had to estimate. There are at least 3 spots where the rust is 1/2 through the square frame. Meaning, the total bottom and side are basically just flake rust.

Aside from frame replacement, I am assuming this is fatal. Can anyone confirm? Picture below.

If so, I may see what I can get on trade. Alternatively, could part it out as there isn't anything else wrong with it.

So sad. Wanted this thing to go to 300k+

[rdruss]

Originally Posted by 2003V8LTD

I'm not totally sure that's fatal. There are a couple of companies that sell weld-on frame reinforcements for a 4Runner. I believe one is called SafeTCap or something like that. I wouldn't give up on it until I have priced out a reasonable repair, because an '04 Limited is a really good thing and would probably last many more years if you get that fixed properly.

What he says. It won't be cheap, unless you are a welder. The Saf-T-Caps aren't that expensive but having them welded on and the prep work can get $$$.

[Bluesky 07]

Checking out theladyviola’s posts on her rust issues and how she addressed them may be helpful. Starts with post #159 on this page of her build thread.

[MikeinNH67]

Fatal or not depends on what you are willing to spend. To determine that you need to check the rest of the frame like the front tow points and under the rear bumper. From what you mention with more spots I'm guessing you're gonna be done with it. Even if you repair it you'll most likely have new spots every year.

You're not going to get much for a trade-in if they notice the rust, someone may give you a decent amount assuming they will repair it or use it for a woods beater. Sad to see these deteriorate like this. I've patched maybe 5 spots myself on mine thus far buying time but doom is only a year or 2 away.

These would fix some of your spots, pricey when including labor.
4 Runner 2003-2009 4th Gen Archives - autorust.com

[Chickenlords]

Thanks all for the responses. I took it to a couple of places that do welding and showed them the car and SafeTcap product. They say it's too far gone to fix and at this point, I would simply need a replacement frame. Rough estimate starts at $10,000 IF I could find a frame.

I anticipated this based on the amount of frame crushing/cracking that I heard simply jacking up the car on it's own weight. It felt unsafe to be under without extra blocking throughout.

I'm pretty disappointed, but there's not much I can do at this point. Hope this is a lesson to others. Protect that frame! Include some sort of anti-corrosion covering on the inside! From what I can tell, a majority of my issue happened on the inside (due to sand/dirt) presumably getting wet. Hope Toyota figures out how to sustain frames as long as their engines! I'm hopeful that the next 4Runner model will be better designed for longevity, if so, I'll find myself back in one in no time.

Cheers!

[Chickenlords]

Here is another photo of the rust. You can stick a screwdriver right into the bottom/side of this. I will try to grab some more later.

[rdruss]

It's really a shame many 4Runners have this frame issue because the rest of vehicle above frame is often almost still perfect. I would bet that if a shop would come up with a replacement frame program at a reasonable(?) price they would get some business to make it worth their while.

Each 4Runner would be a little different with the other necessary replacement parts, but I would bet if a shop could do a total of 12-20 over a period of 5 years it would be a winning deal.

Just need a supply of frames and a willing, skilled shop.

Or maybe I'm dreaming!?

[MikeinNH67]

Originally Posted by Chickenlords

Thanks all for the responses. I took it to a couple of places that do welding and showed them the car and SafeTcap product. They say it's too far gone to fix and at this point, I would simply need a replacement frame. Rough estimate starts at $10,000 IF I could find a frame.

I anticipated this based on the amount of frame crushing/cracking that I heard simply jacking up the car on it's own weight. It felt unsafe to be under without extra blocking throughout.

I'm pretty disappointed, but there's not much I can do at this point. Hope this is a lesson to others. Protect that frame! Include some sort of anti-corrosion covering on the inside! From what I can tell, a majority of my issue happened on the inside (due to sand/dirt) presumably getting wet. Hope Toyota figures out how to sustain frames as long as their engines! I'm hopeful that the next 4Runner model will be better designed for longevity, if so, I'll find myself back in one in no time.

Cheers!

It does suck, I'm kinda surprised no one has been bringing Southern frames to the salt belt areas. Maybe because a totaled truck would have frame damage. Six to eight years ago we replaced the rear half of my son's 04 Ranger (riveted in the middle) because of the swiss cheese, the half frame came from the South. That truck is still on the road because we did the work. It was much easier than a 4runner would be though as we did not touch the cab.

These do rust from the inside out and I haven't seen a really good fix for it. I assume if you had a lift and could wash the frame out then oil the inside it may last way longer.

If I had the time and space I would consider a field trip with a trailer to get something like this.
"NO SHIPPING" 2003 2004 2005 TOYOTA 4 RUNNER FRAME ASSEMBLY V6 4X4 AT SR5 | eBay

[stevelikesrhino]

It fought its life against one of the most brutal salt area (I'm from Iowa too, now living in socal). Expensive, but hopefully lesson learned. I've heard fluid film sprayed inside the frame can significantly prolong the life of inner chassis. Toyota made probably millions of these frame every year, all made in a dedicated steel plant south of Tahara plant, where 4runner and Prado and Land Cruiser and GX are made. Maybe because these truck sold in other countries do not need extra rust protection, maybe toyota did this intentionally, maybe cost, we'll never know. As far as I know, even 4runner and Prados made today aren't undercoated from the factory. It's just what it is, so it came down to owners to do their own protection. A vehicle like 4runner is not meant to be kept in garage, it's meant to be driven, so don't mind all the people bragging their rust free 4r from Arizona or some place (fortunately not yet in this thread), and don't feel bad

[JaSC1]

Is there not something that can be used instead of salt on the roads? Just asking because I don't live in that region.

[Too Stroked]

Originally Posted by JaSC1

Is there not something that can be used instead of salt on the roads? Just asking because I don't live in that region.

Living in the salt belt, I can tell you that there are numerous alternatives. The problem with most of them comes down to increased cost, environmental issues and / or application methods. Those of us that live here have either learned how to protect our vehicles or how to watch them rot away.

[ran]

Oregon does not use salt, not sure what it is. I don't think I have heard of problems with it.
____________
2007 SE V6 Titanium

[Bluesky 07]

As mentioned earlier, I’m beyond grateful to have a clean frame. If I were in the same pickle with rust as many here are, I might at least consider investing in a fix. ~$10K is a pile of cash but still a fraction of what a dealer-new truck costs now. Or put that money toward a clean 4th Gen. They’re out there.

[JaSC1]

Originally Posted by Too Stroked

Living in the salt belt, I can tell you that there are numerous alternatives. The problem with most of them comes down to increased cost, environmental issues and / or application methods. Those of us that live here have either learned how to protect our vehicles or how to watch them rot away.

It just seems weird to me. Destroying/damaging the vehicles the road is intended for in the first place. Kinda self-defeating behavior.