2004 4Runner - RUST --- TSB?

[4RTenn17]

I have a 2004 4Runner and have noticed lots and lots of rust underneath the whole under carage of the 4Runner. This rust does not bother me as much as the rust spot on the rear trunk above the window seal. I first noticed the rust spot looking bubbling with orange rust running down the rubber seal. *I thought this was only exterior surface rust so I pulled out my sand paper, tape, wire wheel and drill. I taped off the area to work on and started with using the wire wheel with the drill on low. And the wire wheel exposed the rust had eaten all the way through the metal and the hole was much bigger than what it seemed. The hole is about 2 inches x 1 inch.

So yeah, rust spot is worse than thought and is now a hole in my vehicle. I am really pissed by now and need some help on thoughts and what I should do now?

***I have heard of people talking about using the TSB and going to their local Toyota Dealer and showing the rust and TSB printed off and they get the rust fixed. Does anyone think the TSB would help in this case? I have noticed some things on the TSB about paint and what not. Please help, thanks.

Location: Above the rubber window seal and almost directly behind the spoiler.

Vehicle: 2004 4Runner SR5 4x4 - Silver

TSB:

TSB for 2004 Toyota Truck 4 Runner 4WD V6-4.0L (1GR-FE) Technical Service Bulletins

 

[DC runner]

Sorry to say, you are out of luck. I believe they did extend the coverage, but I believe it is out of coverage now.

Also. All vehicles rust and it matters where you live and how you use it. Where do you live? Do you make sure to wash your car after a snow storm to get all the salt/road mix they throw down off? Do you leave near the ocean? Salt Sea air speeds up rusting.

I own a 2004 4runner that lived in PA, a rust belt state for all of its live and it is in remarkable good condition because the former owner sprayed it down after every snow and took good rust prevention.

 

[4RTenn17]

I live outside Knoxville, TN. The truck was orginally bought and drove in Binghamton, NY. So yeah I figured out North, Salt, Cold and whatever doesnt help.

*I have read and seen on the forum here a lot of people talking about their 4Runners having rust issues where mine is rusting - come issue seems.

So... is there any way to fix this myself? I really dont have the money to pay a shop to fix it.

PLEASE help people.

 

[chaz]

pics may help.

 

[4RTenn17]

I will try and get some pics shorty in an hour or so and try and post them.

In these cases is it best to just replace the whole rear hatch door? If so where could I get a used door or a new one? I would like to try and get around having one painted or re-painted. And ideas here? Thanks

 

[DC runner]

Yes. Over dealing with bondo.. go to a junk yard and grab one.

Car-Part.com--Used Auto Parts Market


Has always been helpful. It will help you find one near you. Some yards let you go in and pull yourself, others only let their employee's do it; but bottom line is this: Yes. Over trying to fix that and it never looking right, I say try to track down a good one. Even if you need to get it painted, it will look better.

 

[JohnsD90]

I live outside Knoxville, TN. The truck was orginally bought and drove in Binghamton, NY. So yeah I figured out North, Salt, Cold and whatever doesnt help.

*I have read and seen on the forum here a lot of people talking about their 4Runners having rust issues where mine is rusting - come issue seems.

So... is there any way to fix this myself? I really dont have the money to pay a shop to fix it.

PLEASE help people.

Sorry dude, I go to school in Binghamton, almost every vehicle that is over 5 years old has body rust up here. I am not surprised that you are having issues.

 

[4RTenn17]

 

[4RTenn17]

Pics have been posted. Comments?

 

[DC runner]

My honest opinion???? Your vehicle spent some pretty serious time in a place where rust literally eats vehicles. You familiar with the phrase, don't go looking to stir up trouble, because you won't like what you see??

I suspect your vehicle is just eaten up by rust and poking and prodding will only irritate you more. If you try to fix one part, your will uncover more..

I owned a truck like that. I sold it before it fell apart.

You can replace that individual door, but I suspect you have rust everywhere and as you poke and prod, clean, more will become apparent.

So, my personal suggestions??? When a vehcile has spent considerable time in an area that eats cars with rust, a.k.a up north where they salt the roads for months on end... I have 3 recommendations.

1. Come to peace with it. Any car more than 2 years old is going to be rusted up. Learn to love it and drive it till it dies.

2. Or try to fix it and cause yourself untold grief. As you remove panels, rip bolt heads off as the bolt has rusted to the car, as your clean one section only to see it has eaten through entire sections.... you just get more and more upset.

3. Sell it. Sell it before it gets so bad you can't sell it.


I know that might not be what you were looking to hear, but from personal experience; unless you consider that vehicle to be worth a complete tear down, sand blasting... welding new sections to cover rusted out sections.. it is going to be rusty.

Just food for thought.
I would be curious to see what the bottom looks like.. is it just eaten up with rust?? At some point you are going to see structural failure. You did move it down to TN, which will slow it down a little.

 

[chaz]

clean it & maybe try something like a rust converter. Eastwood Rust Converter - Convert Rust in One Step i use this VHT on my underside. VHT Rust Converter 11 oz. spray can

 

[Maritimer]

Well, you have to fix that hole. Some mesh and body fill will do the trick. It's a PITA if it's somewhere highly visible.

I figure it's worth cleaning up what you can find since it will make the vehicle last longer. You will not get rid of it all.

 

[4RTenn17]

Yes, the under body looks like it sit in a river for 5 years, rusted all to hell.

Thinking about taking it carmax, what does everyone think?

 

[DC runner]

No way. Private party that bad boy. If carmax even considers it, which I doubt, they will only give you several grand.

Your best bet, honestly? Be prepared to sell it well below book, and post it private party on craigslist and auto trader. Emphasize the nice trail mod's you have done and see if you can't get someone to take it for those.

Any dealer, carmax included, will take one look at that rust and probably walk away.

Edit: Also, let me tell you, if my advice is coming off as a bit harsh. Let me say, I apologize and I am trying to be as honest as possible. I have been right where you have been. I wanted to literally cry when I had a mechanic tell me, after replacing a ruptured fuel line, that my truck was a goner. He literally told me to watch out for the body coming off. HAHAHA. I sold it the next weekend to a youngster looking for a trail rig. I gave him full disclosure. He said he would probably crash it anyway on the trail. I was lucky I had nice tires and some off road rigging already...

 

[jimithing]

Yeah, it looks mostly like surface rust to me but it's hard to know until you really start trying to eliminate it. If you really like the car then I'd prod a little more and try to see if it's easily repairable. My understanding, though, is that Toyota has had a problem with rust on recent vehicles. I think they did a recall on the Tacoma's because of their rust problems.

I bought a car from Kansas City and it had some surface rust on the undercarriage that bothered me so I've hit it with a rust reformer. So far so good. I haven't gone through a winter with it yet but I like what it did to the rust. I should have taken some before and after pictures. Basically it just turns it into a dark black surface. I was pretty liberal in my application of it and gave it two coats, waiting a couple of days in between.

If you dig further and you're not satisfied with the rust on the car I'd sell it sooner rather than later. It's only going to get worse as long as the rust is active.

 

[DC runner]

Yeah, it looks mostly like surface rust to me but it's hard to know until you really start trying to eliminate it. If you really like the car then I'd prod a little more and try to see if it's easily repairable. My understanding, though, is that Toyota has had a problem with rust on recent vehicles. I think they did a recall on the Tacoma's because of their rust problems.

From personal experience, that type of rust probably worked its way up vs. down. I bet you a buck that is body rust that has eaten its way up from the underbody all the way through.

 

[jimithing]

And this is why I'm glad I live in Texas where we rarely have snow and even when we do we use sand on the roads instead of salt. Sucks for all you guys up north

 

[DC runner]

Yea, I was in TX for several years ago for Grad School. My Tacoma was rust free... one advantage of living in TX.

But, then again, you have to live in TX.


Kidding...sorta.

 

[jimithing]

Yea, I was in TX for several years ago for Grad School. My Tacoma was rust free... one advantage of living in TX.

But, then again, you have to live in TX.


Kidding...sorta.

Hey, I've got no problem with people leaving Texas, more room for me. I wish more people would leave, it's getting much too crowded here. All these foreigners (anyone not from Texas) can take their rudeness and inability to drive and go back to where they came from. :flamethrwoer2:

 

[DC runner]

Inability to drive? I found it to be the other way around. Your flat, straight roads make ya lazy in your massive trucks.

Flame back at ya.