Replacing frame rail # 5

[kgbagent]

Has anyone ever replaced the 2nd frame rail (also referred to as #5 or part # 51201A)? Mine has a 2" hole from rust and sand directly beside the lower support that bolts to the bottom of it.

Or could a custom plate be welded to cover the hole and reinforce it? This part is $564 and probably $500 in labor to replace it.

I am a DIY amateur mechanic, but cannot weld and do not want to learn.

Thanks

2005 V6 Sport Edition 4X4

 

[TowMeOut]

How much of a bear is that to remove/replace? Does it bolt in from the bottom so you can just yank the skid plates and maybe sway bars and remove or do you have to go in from the top? Seems like if it's a bolt-in you could pull one off a junker.

From the top I'm hoping it wouldn't take more than maybe pulling the radiator?? I've never looked...

Other option....remove, take it to a shop to weld/reinforce then reinstall. However, if it's so rusty that you've got a 2" hole in one spot I can't imagine the rest of it is far behind. I'd guess a junkyard treasure is your best bet.

 

[kgbagent]

How much of a bear is that to remove/replace? Does it bolt in from the bottom so you can just yank the skid plates and maybe sway bars and remove or do you have to go in from the top? Seems like if it's a bolt-in you could pull one off a junker.

From the top I'm hoping it wouldn't take more than maybe pulling the radiator?? I've never looked...

Other option....remove, take it to a shop to weld/reinforce then reinstall. However, if it's so rusty that you've got a 2" hole in one spot I can't imagine the rest of it is far behind. I'd guess a junkyard treasure is your best bet.

It appears to be welded, not bolted to the main frame rails. I'm guessing this would be a big bear...a hungry, angry grizzly.

At this point I am going to see if I can have a small plate fabricated and welded over the hole.

 

[V8Man]

[MENTION=75133]kgbagent[/MENTION]
I don't know where you are located in the USA, but if this part is rusted I am guessing others are as well.
I have attached a picture of that area from a rust free Texas T4R. This frame and body are for sale if you want it.:thumb3:

 

[kgbagent]

[MENTION=75133]kgbagent[/MENTION]
I don't know where you are located in the USA, but if this part is rusted I am guessing others are as well.
I have attached a picture of that area from a rust free Texas T4R. This frame and body are for sale if you want it.:thumb3:

That first pic clearly shows the cross member I am talking about. It certainly is welded.

I am in PA, but have been treating my undercarriage for years, so this is the only area with any nasty rusted-through holes. After trying POR-15 years ago based on recommendations here, I have to say IMO that product sucks. (Yes, I followed the prep instructions). I've been seeing great results from wire wheel, then Rustoleum rust reformer followed by brushing on Rustoleum high-performance enamel metal paint.

This cross member has rusted through based on sand and salt entering the hole that faces the front driver wheelwell. Why oh why did Toyota put all these holes in hollow frame members? THIS is a major reason for our rust problems.

 

[V8Man]

[MENTION=75133]kgbagent[/MENTION]
That piece is where the steering rack is attached and the tie rods go thru the middle. It would be difficult to replace.
I am selling this frame and body as it sits for $500. It comes with everything a rust belt guy would need to fix their frame. All the brake and fuel lines, gas tank, exhaust, steering rack, rear end, steering linkage and because it's a Sport it even has the XRAS stuff. I also have another frame but the body is not as good.