A variation on the frame rust epidemic

I own a 2006 Tacoma extended cab. The truck has been continuously licensed and registered in Massachusetts since I bought it new in July ’06. At this point, it has just under 119K miles on it. It is garaged most of the time during winter, and we tend not to drive it much in winter, favoring our AWD car. No surprise, then, that frame rust issues are just now emerging.

I was aware of Toyota's Extended Warranty Program (EWP), but the mechanic who does my basic maintenance says that every time he has a vehicle up on the racks, he inspects the frame and undercarriage. During a routine oil change/tire rotation last week, he reported for the first time a small hole in the frame and suggested that I take the vehicle to Toyota. I did that, and the dealer’s service department confirmed that the damage would have qualified for the EWP, but the EWP had expired, and the only thing I could do is contact Toyota’s national office. I did that, and the case was elevated one notch, but when I got the callback I was told that coverage was denied. I pointed out that the damage did not appear until after the EWP expired, and therefore I could not have asked for EWP coverage during the term of the EWP. I also explained that I bought my first new Toyota pickup in 1984, and have driven Toyota trucks continuously for 35 years. But it was all to no avail, other than a vague reference to a possible Customer Service Plan that might happen down the road, but would probably only cover reimbursement. In other words shell out $12,000 now (crude guess - this for a truck valued at ~$4500 by Kelly Blue Book), and HOPE they reimburse me down the road. I won't be holding my breath on that one!

I plan to file a written appeal and cc the dealer (Boch Toyota of Norwood, MA). I’m not very hopeful, but I know there are a lot of you out there who have dealt with this issue in various permutations, and there's some posts that mention trucks of this vintage still getting the EWP. So I’m appealing for suggestions, especially to those who've gotten frames replaced after the warranty -- what's your secret? I’m thinking it’s probably not worth it to retain a lawyer, but if anyone has had success going that route, let me know. Otherwise, any advice on strategies and arguments that might help would be much appreciated.

Cheers

-=David=-

 

There have been dozens on here who say theyll get a lawyer and fight/appeal the issue. No body has won a case yet. I wouldnt even waste the time.

 

Unfortunately you are SOL. On the bright side you did get 14 years out of the vehicle, and will probably get another few as well.

 

Welcome to the forum on a shitty note David
Patch it up and sell it disclosing the repair to the frame.
It will still fetch a pretty penny.

 

All '05-'10 Tacos were covered until January of 2019. My '06 was a Canadian sold truck, so mine was covered until July 21, 2019. I made sure to very, very gently find a hole before my deadline and got it inspected and approved. If a hole just appeared on the OPs Taco, it's pretty much for sure that a hole could have been encouraged 1 year ago. I'm not talking about trying to cheat the system. I'm talking about gently flaking away metal that is already compromised. For anyone in the future that attempts this, make sure it's not obvious that you encouraged the hole, or you're permanently screwed. Sorry OP, but there's no hope of getting a free frame out of Toyota. 12 years is a very long time for a manufacturer to stand behind their product. Granted, the courts made them do it, but that's only because the Toyota drivetrains last ~400K miles and the frame did not.

 

I know little to nothing about welding or metallurgy etc. but I always wondered what the reason was for not patching rust holes in the frame? Like cutting out the damage and welding in a new piece...

 

There is a company up north i saw recently on here that does rust prevention and frame repair. I thought i screen shot it but didnt and i looked but couldnt find it again. If you look maybe you will have better luck than me finding it. I even looked at there website and it looked like they did a great job of frame repair. Sorry to hear about your frame. Good luck

 

SafeTCap makes frame kits for 1st Gens.
Maybe call a shop that installs them in Mass?
I’d see if any are close to you. Then ask if they would be interested in looking at a 2nd Gen?
Maybe one of them could attempt a repair?
https://www.autorust.com/safetcap-installer-network/

​

 

There is nothing special about the steel in our frames so welding on them is no problem as long as it's done correctly. The SafeTCap frame repair kits are really popular with the Jeep community. I didn't notice a 2nd gen Taco kit bit didn't look very hard either.
https://www.autorust.com/safe-t-cap-kits/

Edit - looks like Shooter beat me to it.

 

wow..

 

I feel you pain, but let's look at the cold, hard realities of your situation. The issues with Tacoma frames are well known and all over the internet. Said another way, it's hard not to know about the problem, Toyota's programs, and what needs to be done to qualify for a frame replacement. And you said you were aware of Toyota's program. All you needed to do was take your truck in to a Toyota dealer and have them inspect the frame to qualify - yet you didn't. Sorry, that one's on you.

Second, even though it was ordered by a court - what amounts to a 12 year frame warranty is completely unheard of in the industry. If Ford, FCA or GM had similar issues with their frames, you'd be SOL after your 3/36 factory warranty ran out - period, end of report, mile drop. Bravo for Toyota.

Third, you said your mechanic inspected the truck - and the frame - on a regular basis. I find it hard to believe that 1) He didn't know about the frame issues and programs, and 2) He didn't see evidence of the frame rotting out well before it did. Frame rot takes a number of years to get to the point of no return and gives plenty of advance notice. Shame on him.

So as others have said, yes, you are SOL on this one and no amount of pressure on Toyota is going to get you a new frame for free. Sometimes we just have to take responsibility for our own actions - or lack thereof - and suck up the consequences. This isn't Toyota's problem, it's yours.

 

In defense of Rockbridgeboy my first gens frame was replaced. Always been a toyota fan and finally purchased first tacoma in 2010. Was garage kept and lived in a low salt area, didnt appear to be rusted when i bought it. Fast forward six years, i live in a heavily salted area. Thats when i first found tacoma world ! My rear locker quit working. Found how to fix it on here and crawled underneath, while reinstalling it I noticed my frame had a nice big hole. It was inspected 2 months prior! Luckily when i called toyota i was eligible for a frame. I now have a 2013 and received recent frame letter. Ive been fluid filming this one. Point is i had same situation and i thought i knew toyotas. But it wasnt till i got on here and started searching. Since then my wallets took a big hit because of mods. Not sure if you use internet much rockbridgeboy but i just looked for that shoo again but found others that fix tacoma frames. Point is if toyota doesnt give you knew frame which sorry to say as too stroked mentioned they prob wont. But if you like your tacoma and with the low miles it prob be worth repairing if its not to awful bad. Either way hopefully it all works out in the end.

 

Rajah

 

The 2006 Toyota Solaras had a cracking dashboard condition. They said they sent out recall notices for the condition that I never got. I went the same route as you after the recall expiration to no avail. It was like talking to a wall.