My '03 Going in for Frame Inspection in the Morning - Fall Update

It's time for my annual Toyota extended frame warranty inspection. That and my NYS annual safety inspection.

I was under the truck today and I can surely say that there is no obvious sign of a rust through anywhere, particularly in the usual trouble spots. This is despite the the rusted off gas tank skid, engine skids and surface rust everywhere. The OEM bumpers were replaced three of four years ago due to rust. She shows her age with all the rust on the underside. Our warm weather state members would take one look and run screaming into the night.

I've asked for an assessment of the condition of the frame, and a prognosis. "How long has she got, doc?" I'm under warranty for another year or so, but would like a second opinion on where I'm headed. I'd like to keep the truck for as long as possible, but without taking heroic measurers.

This truck entered service in Maine (a cold weather state by all means). Then lived in Massachusetts (a bit warmer, but still cold). I bought it in NJ in 2013. It's been with me in New York since then (another GD cold weather state). Do you like salt on your Taco? In NY they pre-treat some roads before a snow storm with salt water. Don't they know there are Toyotas out there?

So, we shall see how his turns out, this year anyway, in the morning. I expect to pass both inspections (CEL not on, all lights work, relatively new brakes, emergency brake cable and tires, and new headlights). But it would be nice to get another new frame on Toyota (my old '01 got one back in 2012).

 

Well, frame passed, but the truck did not pass the state safety inspection. Seems that I should have replaced the front corner lights when I did the headlights. NYS says I can't tape them in place. I had forgotten all about that, otherwise I would have replaced them already. So off to Amazon to order a cheap pair of aftermarket lights to get this to pass. The OEMs are $200 a pair installed.

Sidenote on the frame: the service manager says it's thin in a few spots, and that the rear diff is is rusting pretty thin also. He says since I have another year on the warranty, be sure to bring it back in before the warranty ends as the rust may progress to the point it qualifies for replacement. I also have the passenger side water leak on the front floor. Who doesn't? I'll look into that on my own. Otherwise, they found no other issues. LBJs check out fine (130K miles on this set). So I'm in for another year.

I'll take a few pictures of the underside later today.

 

It was too dark for picture when I got home last night, but here are a few in the daylight.

Those shackles and springs are not OEM, but from the lift I did back in 2011 when I had my '01 (Wheeler's 5 leafs, OME 880s). I swapped suspensions between the '01 and '03, then sold the '01 (with a new frame-sometime I wish I kept that one). This rust is pretty typical for my area on a 14 year old truck. Of course that goes X2 for Toyotas. This is not bad compared to some of the rust throughs documented here. A few areas of the frame are thin according to the service manager. I should have asked which areas.




I have looked at a new gas tank skid on LowRangeOffroad, but holding off for now. If the frame does go in the next year, I would probably upgrade quite a bit of this rusted out stuff, and probably do a new lift/shocks/struts. You know the money just flies out the door once you start.

 

I wonder, nobody does fluid film on the rust band? Or it does not work there?

 

Wow, that is incredible to see this. I certainly agree that it's nowhere near as bad as other p is I've seen. What does the bed look like next to the wheel well? I'm curious why you traded in your new frame 01 in on a 03?

 

Mine has been done every year since new, inside and out in the rust belt. My frame is dirty but no rust that I have seen on the frame. Skid plates they have rust. Yes it does work in my mind to slow the rust.

 

Who was that Canadian Official who said "I must have been in a drunken stupor at the time."

If selling the '01 wasn't bad enough, I bought the '03 without checking that it had been undercoated by Toyota. This after Toyota bought back my '97 TRD and my '00. It was a long distance buy, and I wanted a newer truck with more features and lower mileage. The '01 was a base model, no options, 225K. I regretted it right away because I had a solid truck in the '01, could have saved $12,000 (purchase price, tax and tags, tires, parts, etc.), and would not have had to swap the suspension. That's when I first realized how bad the frame was. Fortunately for me, the PO took the truck in for all the required maintenance. I guess I had blind faith in Toyota. They had been very good to me with the buy backs and the frame replacement.

I sure know about fluid film now. If it were not for the way the service manager suggested (hinted?) that I have another year on the warranty, that the frame is thin in several places, and made sure I knew to get it back there before the warranty expires, I would be treating the frame today. I'm going to let it go as is and let the corrosion take its toll. If it does hold up, then I'll have to consider making repairs and treating the frame. It could be a gamble.

 

I should add that the '03 runs and rides great. It's taken 4 years to clear up the stream of codes it kept throwing, but she's solid now (with the above mentioned exceptions).

 

mine look worst and they say they will not replace

 

Fall update:

Today I was dong a quick inspection of my truck, specifically checking the frame. I reached a finger inside the frame and found any number of rust flakes, most too big to fit through the vent hole. In addition, there is about a half inch of sediment on the bottom of the boxed in section. This is the driver's side, leaf spring front mount area.

It's no wonder that we see so many rust throughs in this area. The sediment drifts toward the rear with every acceleration. Once water enters the frame and soaks into the sediment, I don't think it can ever dry out completely. Most of the water will drain through the weep holes on the bottom, but a damp layer of dirt and rust is left behind to work its magic on the inadequately protected steel of the frame.

Currently, there are no perforations in this frame, but there are significant signs of rust damage occurring on the inside of the frame. This frame is under warranty until august of 2018.

 

I guess your idea is as good as the next It would really suck if Toyota just decided they had enough and ceased operations in the USA

 

Yeah, that would about do it for me and this truck.

 

Looks just like my 03 taco. I took in this year and they also told me it was fine, just a lot of surface rust. Does the clock start at the date of when the truck was sold or on the date that it was treated (undercoated)? i can't remember, but i think they told me i only had till Oct of this year and out was out of coverage. The OP says he is covered till August of next year, thats why i ask.

 

You think you have it bad, look at my location !! Think they start salting the roads here in August! Lol. Good luck with yours but hope it goes bad before next Aug so you can get a new one.

 

i buy LPS3 by the case. I liked the older formula better though, it flowed longer but since that was the VOC part of the formula, I'm betting they took some out to be more ''green.''

 

The extended frame warranty is 15 years from the "In Service" date, which is usually a short time after the manufacture date on the door sticker, provided the owner fulfilled all the requirements to maintain the warranty. Mainly, for cold climate vehicles, this was inspection of the frame and the application of undercoating by Toyota (at no cost to the owner) before the deadline (12/31/2011 or so, depending on your state).

My manufacture date is 8/18/2003, and the original sale date is 11/26/2003 in the state of Maine. So I actually have a bit more time, but I've not confirmed the later end date with my dealer. I will not see them again until June next year, unless the situation worsens before then.

 

Do they use the brine there also? Probably do on the state roads, just like here. This one also spent time in Auburn NY, then the Boston MA area. I bought it in NJ in 2013.

Well, time will tell. I should take bets on how long it will last. Although, its looked this bad almost as long as I've owned it, so it may be tougher than it looks.

 

One reason I deferred any rust countermeasures was because I never thought the frame would make it this long. If it should be replaced, I don't care what they say, it's going to get the full treatment. If it holds out, I may look for a donor frame. It'd then be my little frame swap/restoration project.

 

I looked up my service records online and did not see anything about the previous owner bringing my new-to-me ‘03 in to the dealership for a a frame inspection. I suspect I should contact Toyota anyway and see if I still qualify....maybe it was done and not documented? My stuff looks like surface rust, but it still would be awesome to get a whole new frame!

 

If you've got it, there would be a sticky black layer on the frame and everywhere else they sprayed the stuff. Even though a lot of mine has flaked off, you can see plenty of it in the last picture. You can also see how easily it come off on your hand when working around under there. NY's deadline for the undercoating was later than most other states, 12/31/2012 I think. My old '01 failed inspection and had its frame replaced in the fall of 2012. I was taking it in for the undercoating before the deadline, and came out with a new frame.