Killer of my 4runner - RUST

[hour]

I'm pretty set on keeping this thing until it explodes - if the motor, transmission, etc. goes - replace. But I have this problem that's getting worse rather quickly and was hoping to gain some input. Most of the threads I found were on previous generations, and a 3rd gen thread kind of fizzled out with no pictures posted.

Anyone handled this on their own, or had a body shop take care of it (if so, $?)

The windshield has Toyota printed on it, has zero cracks or microscratches - so I'm not sure how this happened. A lot of my reading has indicated that crappy windshield seals contribute to moisture and grime -> rust... but beats me if it's factory glass.

I'm cool with trying my hand at repairing the rust, at worst I can wire wheel it, use bondoglass if necessary, prime/rust inhibitor, and crudely paint. I suppose the biggest hassle in that is having to get someone out to yank the windshield, me finding the time in the quickly approaching winter to do the repairs, and then having the glass reinstalled (or replaced if they break it on extraction). Again, input/stories/words of wisdom appreciated. If it gets much worse I feel like I'm going to be screwed big time - rest of the vehicle is pretty clean and rust free (surface rust underneath) and it's been in CO its entire life. No leaks, yet.

But it gets much worse...

And worse still...

When I bought it almost a year ago (2 weeks til anniversary), this spot was the only one I noticed. A couple of months later I found the rust under the gasket, and just recently the spots to the sides of this large one appeared but seem to be the most minor of all

And yep, it's on the passenger side too, though concentrated here - very little under the gasket

 

[allwheeldrive]

Thats a major bummer, especially when its the oem windshield and unmolested. Drive it into the ground now!

 

[xcmtb83]

Fear not. My Tacoma was rusting like that too but a friend of mine sandblasted the rust out once the windshield was removed then followed up with primer and paint and clear coat. The blend wasn't perfect on the roof but it is one the roof so who cares.

 

[MStudt]

That's not bad at all. I'd take care of it now before another winter does more damage. I thought I was going to see a frame cracked in half, or a rear out axle. Instead, it's just surface rust with a small hole. Sand those spots down, use navel jelly, prime, and paint.

 

[Ghostrider]

Yep = fixable with the windshield out. I did it a long time ago on a different car. Pulled the windshield, sanded down, primed etc....

 

[Nelsonmd]

I have it way worse than that. When I last got my windshield replaced, the guy showed me how bad the rust was and said that he couldn't guarantee the seal. I am to the point of losing the metal entirely.

If you're not leaking, then I'd say spray some WD-40 down there and leave it til you need to replace the windshield, then clean it up. You can sand and paint the visible parts if you want, but it won't match that well.

 

[amalik]

hour -- i'm a little surprised to see this from a CO truck... wth?

 

[hour]

hour -- i'm a little surprised to see this from a CO truck... wth?

Yeah dude. Me too. I have rust under the drivers side tail light where the previous owner must have hit something, but that's understandable - the paint was chipped.

That's why I mentioned my findings of culprits, reading people saying it could have been due to a crappy windshield gasket/flange thing.

Sorry to spook anyone or give the impression that it's worse than it is, but in my opinion, I can't see a logical/cheap way to replace the whole frame without cutting out and welding in donor metal from god knows who. That's wayyy beyond my capabilities and undoubtedly more than I'd ever want to send. Water getting down in to the instrument cluster would also be a disaster. Because of that, this will kill my runner if I don't address it and allow it to become unrepairable or fry crap from a leak.

Looks like I'll have to investigate doing what some of you suggested- having windshield yanked, ideally having guy not break the glass, storing that, having a tarp and tape prepared for masking the area until I'm done with repairs and the glass in reinstalled, yadaya. I WISH I HAD A GARAGE!

Not concerned about paint match. In fact, if there were clean lines to follow from the frame all the way over the roof, I'd just paint them + the roof black. I think it'd look pretty bad since the doors curve and there's no straight line to follow back above them and all the glass. I also have desert tan flat single stage auto paint that I ordered with plans of a full repaint DIY in future.

For now, I may just prop the windshield gasket up with airline tubing (think little air pumps for aquariums), tape outside of the rust areas to protect the existing paint, sand like a madman down in that gap and use a dremel + tiny wire cup brush I have, vacuum out the dust and stuff, use compressed air to blow it out more, then rustoleum it or something. I know I won't get everything so maybe I'll follow up with the WD40 suggestion, just to get me to Spring without any additional damage.

Thanks all