google searching for exactly what I'm looking for has been difficult. lots of anecdotal stuff, one court case.

Got word she wont pass inspection anymore due to frame rust/rot. I've done a ton of frame restoration grinding/priming/painting to extend the life but of course you can't stop it from rusting from the inside out. dealership did a report and took pictures but kinda just said call customer care and wasn't extremely helpful.

over the years i completely replaced the suspension, DT headers, sound deadening, sound system etc etc so i'm really not trying to take a total loss here.

so looking for tips & tricks to engage toyota on a replacement. I'm formulating some evidence & arguments to just cold call customer care but would rather investigate known working methods.

That sucks man.

I remember visiting my dealer years ago and seeing a stack of brand spanking new beautiful frames sitting in the bays, but outside of the official recall (didn't include 4runner), I'm not sure anyone has had success with Toyota for a replacement.

And I know you were asking about help from Toyota, but several brave souls here have attempted it themselves with success if that's your flavor.

Anecdotal replacement costs (don't quote me, I just remember seeing astronomical numbers) from a dealer are like $10k plus...

thanks, i believe the frame itself is 6k and the labor is around 10k.

I'm capable of doing something like that i just dont have the means. living in the city...

Yea, unfortunately, you wont get anywhere with toyota and will likely just make yourself more upset and frustrated. You can lodge a complaint with the BBB and thats about it.

Id try something like this myself if youre looking to save the runner. though its inevitable more spots will likely come up

nothing you can do when they salt the roads half the year

4 Runner 2003-2009 4th Gen Archives - autorust.com

i have mostly mentally prepared for that frustration yeah. but your link is something i had not come across at all so thank you. its another possible pathway back to safety and inspection.

I knew mine was getting bad, but I was hoping to squeeze another year or two out of it.. But last night I pushed my finger through the frame.

Cut the bad out and weld in some new. As long as it's a flat spot it's pretty easy. I have a new spot I have to repair soon.

Buy a replacement frame from Toyota. I think they're 3.5k.

Try going to the small claims route. If you are outside the actually city of philly, you can file with your local magistrate. Limit is up to $12k. You can make your case and see where it goes. Best case is Toyota does not show up and you get a default judgement. Would be a couple hundred for filing / server fees. PM for more info.

If you are in the city, not sure how that court system works as they have their own way of doing stuff.

Good luck!