Frame rust

note to OP: After you get your truck back with the new frame you may want to consider oil undercoating. There is a guy named David Heath in Loudon NH (just outside of Concord) that does hot oil undercoating (I think he uses chain saw oil cause it sticks). I did mine right away. He charges about 100-150 bucks for the application and even sprays into the doors. His phone is 603-798-5895. You can call for more information. He is very busy during the summer and you need to set appointment.
 
note to OP: After you get your truck back with the new frame you may want to consider oil undercoating. There is a guy named David Heath in Loudon NH (just outside of Concord) that does hot oil undercoating (I think he uses chain saw oil cause it sticks). I did mine right away. He charges about 100-150 bucks for the application and even sprays into the doors. His phone is 603-798-5895. You can call for more information. He is very busy during the summer and you need to set appointment.

Just read up on this. This is genius!
 
note to OP: After you get your truck back with the new frame you may want to consider oil undercoating. There is a guy named David Heath in Loudon NH (just outside of Concord) that does hot oil undercoating (I think he uses chain saw oil cause it sticks). I did mine right away. He charges about 100-150 bucks for the application and even sprays into the doors. His phone is 603-798-5895. You can call for more information. He is very busy during the summer and you need to set appointment.

I'm assuming he also sprays inside the frame? sounds like a pretty cool option for the mag crap they spray on the roads. My neighbors think I'm crazy when I'm out there in 30 degree weather hosing off the underside of the truck but it's totally worth freezing my a$$ off to get that crap off the truck frame and suspension components.

To anyone considering undercoating or rust protection, don't forget to protect the inside of the frame. I've seen a good number of folks who go to the trouble of protecting a vehicle's underside, only to forget to coat the inside the frame. And it rusts from the inside out!

Here's one option I've seen that gets decent reviews. Obviously the hot oil coating is a great idea too!

Internal Frame Coating
 
Thanks, I'll consider that.

I'm starting to think about what other maintenance I should have them do while the truck is torn up. I'm due for a new timing belt next year, so I might as well have them do that when they do the frame, as they will have easier access to the engine and it will save about an hour of labor.

My XREAS shocks are original and I'm not sure they can transfer the system without replacing it, so I think it is time for new shocks and springs. I'll probably stick with stock springs and maybe Bilsteins.

Since I'm losing XREAS, I might update to solid sway bar bushings.

I'm wondering if it is worth it to have them open up the transfer case and replace the seals and o-rings. Normally that is a hugely expensive job due to the labor to drop the transmission, but since they're already dropping the drivetrain, the labor should be a lot less.

Any other suggestions?
 
I would love to have an Icon FJ44. He not only powder coats the frame -- he powder coats the body. Just as soon as I win Powerball: ICON

Are you diligent about washing road salt off of your rig, including the underbody, after every winter weather event? I've got an '06 which I've had in New England since 2011 and mine only has superficial surface rust on the frame and other underbody components. In fact, when I got my state inspection back in October I asked the technician who had it on the lift how bad he thought the rust was and he said he wouldn't have believed it was an '06 if he'd only looked at the underside.

As soon as the roads dry after it snows I run it through one of those touchless car washes that sprays off the underbody as you drive into the bay, because the best way to prevent that corrosion is to get the road salt off of it as quickly as possible. I've also never had it undercoated.
 
I'm assuming he also sprays inside the frame? sounds like a pretty cool option for the mag crap they spray on the roads. My neighbors think I'm crazy when I'm out there in 30 degree weather hosing off the underside of the truck but it's totally worth freezing my a$$ off to get that crap off the truck frame and suspension components.

To anyone considering undercoating or rust protection, don't forget to protect the inside of the frame. I've seen a good number of folks who go to the trouble of protecting a vehicle's underside, only to forget to coat the inside the frame. And it rusts from the inside out!

Here's one option I've seen that gets decent reviews. Obviously the hot oil coating is a great idea too!

Internal Frame Coating

I wonder about the long-term results of using that internal frame coating. Does it actually help? I'm afraid I wouldn't be able to get the inside of the frame clean enough, and it would just trap more water in the rust and dirt that's in there.

Could Toyota deny a frame replacement if you coated it and it eventually fails, since they can't control what you put on?
 
When it comes time to do your timing belt, you may want to consider Rons Toy Shop on Elm St in Manchester NH. The shop specializes in Toyota and is way cheaper than the dealer. Brad Fournier is a master tech there (family business)who also has a 4Runner and is a member here on this forum. When I bought my 04 V8, about 2 years ago, I had a shit load of work done there including timing belt, water pump, thermostat, serp belt, sway bar bushings, PVC, spark plugs, oil change, and 4 wheel alignment. The total cost for parts and labor was 1187.00. They even did a few things for free such as changing the face plate on the display panel, greasing up underneath and most importantly they heated up the cat and blew out the residue to get rid of the P0420 CEL code. The CEL has never came back on, and they did not charge me.
 
I just got a call from the dealer -- my frame has arrived. I'll be dropping off my 4Runner next Wednesday. The dealer told me to expect it to take a couple weeks.
 
I dropped off my 4Runner today. I was pleasantly surprised when they gave me a Camry loaner. I was worried that I would be stuck in a Yaris for 2 weeks.
 
I dropped off my 4Runner today. I was pleasantly surprised when they gave me a Camry loaner. I was worried that I would be stuck in a Yaris for 2 weeks.

Well, you did still pay $1K, so you deserve AT LEAST a camry. (also could be all they had, it happens to me. Depending on availabilty, I'll get Corollas or new RAV4..................). Anyway, this is why I tried to wash my underside as much as I can even if it's 20 degrees. Try to take some pics before and after (if you can). Reminds me of when they replaced the main wire harness/engine harness/ECU/battery/injector/ on mine ................. don't ask, long story.............. For that, i was given a Prius (don't laugh, I actually like it). My 4R was at the dealer for about 2 months.
 
Didn't get a chance to take any before picks. You know the cross-member under the transmission? That is a tube. Mine is now effectively a U channel - the bottom surface is gone.
 
I'm still surprise on how they are good-willing most of the cost. Good luck and congrats on the new frame!

Not sure what your plans are afterwards (keeping it forever or selling it), but I know I would be constantly keeping that new frame spotless during the winter. Those chemicals they spray on the road are absolute MURDER on everything. They spray that shit here in PA too.
 
I'm still surprise on how they are good-willing most of the cost.

I'm not. I think there were fundamental design and or specification problems with the T120 frames.

Not sure what your plans are afterwards (keeping it forever or selling it), but I know I would be constantly keeping that new frame spotless during the winter.

I'll be keeping it for a while. Given my schedule with long commute, work, house to take care of, etc., I don't have time to constantly wash it in the winter. Not happening. If it lasts another 8 years, then I will have gotten 20 years out of the truck. That's more than enough for me.
 
I'd hoped to keep my '03 4Runner for at least another 50k miles. Unfortunately, my mechanic is telling me that I've got holes in the frame. I'd seen some significant rust on my frame cross-member a few years ago, and I did my best to grind it down and paint it with rust-converting paint. I'll get back under the truck tomorrow to take another look.



Last I heard, while Toyota recalled Tacomas for frame rust issues, they did not recall 4th Gen 4Runners, even though they use the same frame.



Has anyone gotten help from Toyota for 4th Gen frame rust?


The tacoma and 4Runner are not the same frame. The tacoma is made in the U.S. and 4Runner is made in Japan. The "faulty" frame on the Tacoma is made by dana corp. even though the recall was not of a big a deal as its made out to be.
 
:party:
The tacoma and 4Runner are not the same frame. The tacoma is made in the U.S. and 4Runner is made in Japan. The "faulty" frame on the Tacoma is made by dana corp. even though the recall was not of a big a deal as its made out to be.

The basic design is the same. The specifications are the same. Yes, the 4Runner frame is made in Japan and not by Dana. But if you look at the premature rust (and I did get rust through holes prematurely), it is similar to where the Taco frames rusted.

I don't think that Toyota would be spending thousands of dollars replacing 4Runner frames unless they knew there was an issue.
 
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:party:

The basic design is the same. The specifications are the same. Yes, the 4Runner frame is made in Japan and not by Dana. But if you look at the premature rust (and I did get rust through holes prematurely), it is similar to where the Taco frames rusted.

I don't think that Toyota would be spending thousands of dollars replacing 4Runner frames unless they knew there was an issue.

You really don't get it. The frames are not the same, the specs are not the same, and all steel will eventually rust. The Tacoma frames rust at a much higher rate, and frames in the rust belt even faster. You live in the rust belt. I am pretty sure if you posted a picture of the underneath of your 4runner that we would see there is much more than just the frame rusting. If you look at the Tacoma, especially the first that were recalled, the frame really stood out with much more evident corrosion.
 
Toyota would not be spending $8k to replace the frame unless they believed they had some responsibility.

You're not worth responding to further.
 
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Im glad you are having good luck with yours. I have been trying for 2 years, and I keep getting told Im out of warranty.
 

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