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Old 09-13-2020, 03:47 PM #16
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Well, just had a look around. I'm not seeing any signs of thru-the-frame rust anywhere. Areas of peely surface crust, with prior undercoating, in many spots. The brace shown above, which the front of the belly pan attaches to, is pretty bad and needs to be replaced, or re-done.

The other issue is the front brackets for the running boards, on both sides, are rusted and broken, leaving the front ends just hanging there. I never step on them. Someone suggested to me that a shop may have used the wrong lift supports and snapped them, not sure how much credence to put in that. I was planning to either remove them, anyway, and possibly replace with nerf bars. I hope the bars could still be installed, but it would be rusty mess removing the bad bracket pieces, would probably need new brackets all the way down.
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Old 09-13-2020, 04:19 PM #17
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Originally Posted by sport2004 View Post
Well, just had a look around. I'm not seeing any signs of thru-the-frame rust anywhere. Areas of peely surface crust, with prior undercoating, in many spots. The brace shown above, which the front of the belly pan attaches to, is pretty bad and needs to be replaced, or re-done.

The other issue is the front brackets for the running boards, on both sides, are rusted and broken, leaving the front ends just hanging there. I never step on them. Someone suggested to me that a shop may have used the wrong lift supports and snapped them, not sure how much credence to put in that. I was planning to either remove them, anyway, and possibly replace with nerf bars. I hope the bars could still be installed, but it would be rusty mess removing the bad bracket pieces, would probably need new brackets all the way down.
Often times the rust holes aren't identifiable with a visual inspection, unless its really too late and they're pretty big. Most times, they're hidden under some flakes that only appear as surface rust. Based on how the front frame and skid mount looks, I'd bet there are a few rough areas around the frame. A needle scaler will very quickly beat away any deteriorated metal and uncover any holes that need attention. An angle grinder with wire wheel is another option, but it can be difficult to control in the tighter areas.

For the running boards, I'd just remove them. Looks better without them on, and sounds like you already step over them to get in.
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Old 09-13-2020, 09:37 PM #18
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Originally Posted by Monty87ls View Post
Awesome thanks! Im def gonna look into this swell as part of my frame restoration project... Whenever the might be.

I def think that the drain location has a major effect on the rust on the passenger side of the frame. Get enough people maybe it could help the lawsuit.. Is that even still going?

I contacted Toyota Customer Service (800-331-4331) on 5/26/17 and reported the problem about A/c condenser drain and frame rust on my '03 Ltd. I sent them pictures too. They assigned a case# 1705262470 and a ref# 170526-000254, but that's the last I heard from them.
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Old 09-13-2020, 10:31 PM #19
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They had to do it with the Tundra as well. There has been a lot of talk here over the years about this, but nothing conclusive regarding our 4Runners other than a mention awhile back about the NTSB doing an investigation on it. I suspect the whole Covid mess has really delayed such inquiries though.

I called the NTSB also and they took my information and just said the investigation is ongoing.
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Old 09-13-2020, 10:32 PM #20
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Originally Posted by rdruss View Post
I contacted Toyota Customer Service (800-331-4331) on 5/26/17 and reported the problem about A/c condenser drain and frame rust on my '03 Ltd. I sent them pictures too. They assigned a case# 1705262470 and a ref# 170526-000254, but that's the last I heard from them.
I called them about my frame issues also and the made a claim number and all that but it will never amount to anything. Im hopeful the NTSB investigation will lead to something.
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Old 09-13-2020, 11:02 PM #21
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Helpful, thanks!
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Old 09-14-2020, 08:14 AM #22
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I just filed a safety complaint with the NHTSA. My rust is bad in parts.
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Old 09-14-2020, 08:54 AM #23
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I just filed a safety complaint with the NHTSA. My rust is bad in parts.

Yikes! I would def get someone to look at that and see what they can do asap. I didn't really have the money but wanted mine done before winter, and I still need to clean it and coat it in something.
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Old 09-14-2020, 05:32 PM #24
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I went all around mine with a pointy body hammer, luckily the front end was fine but I created new holes in some of the bottom horizontal sections. I also had a tank strap break, removing the frame bolt created another rust hole. I've welded 3 or 4 patches on my rig so far. All of the guards turned into crumbling crackers so those were all removed by me. The needle scaler is definitely a good tool for this job. In my opinion I think the best thing to do is oil the frame inside and out with an oil that sticks well, Fluid Film didn't last a winter on my truck.
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Old 09-14-2020, 07:56 PM #25
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I went all around mine with a pointy body hammer, luckily the front end was fine but I created new holes in some of the bottom horizontal sections. I also had a tank strap break, removing the frame bolt created another rust hole. I've welded 3 or 4 patches on my rig so far. All of the guards turned into crumbling crackers so those were all removed by me. The needle scaler is definitely a good tool for this job. In my opinion I think the best thing to do is oil the frame inside and out with an oil that sticks well, Fluid Film didn't last a winter on my truck.
I agree, and once all my welding is done, I will be using an undercoat gun to shoot some heavy oil inside the frame! After seeing a thread about the AC drain dripping on the frame, I checked that today, and found that it rusted a hole through the top where it drips, and rotted out the bottom directly below that! WTF Toyota?!
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Old 09-14-2020, 08:02 PM #26
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Here is a a couple pics to show what that stupid drain location caused!
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What can I do about this RUST?-3e7a97b5-ebfe-49e7-bab0-a6ce4b7ad7b4-jpeg  What can I do about this RUST?-63bad185-4119-44ee-b2dc-ed6e7ab9ac44-jpg 
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Old 09-15-2020, 05:29 PM #27
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I agree, and once all my welding is done, I will be using an undercoat gun to shoot some heavy oil inside the frame! After seeing a thread about the AC drain dripping on the frame, I checked that today, and found that it rusted a hole through the top where it drips, and rotted out the bottom directly below that! WTF Toyota?!
I bought an undercoating gun with a wand off Amazon recently, haven't tried it yet.

Dang, I moved that AC drain hose a month ago and didn't see any corrosion from it. Odd how these things seem to rust differently car to car. That one looks like a pain to repair.
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Old 09-16-2020, 09:44 AM #28
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Just saw a sobering Youtube video...had the same problem with the front brace, one side had been repaired, also had two or three fixes along other spots on the frame, plus much of flaky rust all over.

I'm not sure I want to deal with this. I was planning to do some body work, exhaust system, to the tune of thousands. Not sure that would make sense with the rust issues. Maybe I should swap this out and get a later model, don't want to leave the club.
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Old 09-16-2020, 10:12 AM #29
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It does suck, on the plus side these are fully boxed frames that are pretty thick unlike something like an older Ranger. Those things break in half if the rust isn't noticed in time. If you can afford to get a newer cleaner one then I would say go for it just make sure you oil the inside of the frame vigilantly. Sadly you now know the value of your current rig is probably less than what you paid for it left as is.
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Old 09-16-2020, 10:31 AM #30
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Maybe someone will come along and talk me off the ledge...LOL

Lower mileage Gen 5's seem to be in the 20K+ range...but I don't want a Gen 5!
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