Frame Rust Advice for Inspection

Hi,

I should start by saying that my frame is not the worst I’ve ever seen, nor the best either (but open to opinion from the forum world).

Vehicle Details

- 2011 DCSB with 113,600 miles
- At the time of sale, Car Fax had showed the vehicle in Virginia from 2011 to 2015 ‘ish from memory and in California from 2015 to present day.

I’ve got an upcoming appointment at Toyota for a frame inspection on my 2011 DCSB (with 113,600 miles). In speaking with Toyota Customer Service, they were able to reference a Customer Support Program for the vehicle which was the ZKA Vehicle Frame Perforation. In this, it stated that any rust 10mm or more warrants a replacement frame - does anyone know what the 10mm is referencing to i.e. is this 10mm across a horizontal surface?

The inspection stems from another issue I’m having...

Whenever I go over speed bumps or semi decent bump in the road, the rear undercarriage produces a clunk noise, almost like something is loose within the bracket of something else. I’ve gone underneath on multiple occasions to check nuts and bolts, to no avail. On a recent trip to Toyota (a different dealership to the one the inspection is booked with), they couldn’t offer much insight into what could be causing the noise and said that until the rust is looked at, they can’t give much more feedback on the issue (which I was a bit disappointed in their effort, but moving on). One guy had told me that it could time to replace the bushings on the springs with a polyurethane type. Before jumping to the first thing I hear, I am trying to gather more information on the matter, but nonetheless, the feedback I have been given has lead me to get the frame inspected.

In terms of rust, the leaf springs and tow hitch are in worst condition than the frame itself, from what I can see. Upon purchasing the vehicle, I also bought an extended 36 month warranty, which I hope can at least offer me a new tow hitch/leafs or at least some reprieve in replacing them (which I know is a decent ask).

Below are the areas of the undercarriage. Again, some areas are quite good but some need some attention. Prior to the inspection, I am wondering if anyone can offer any advise/recommendations or general tips to keep an eye on?

Thanks

 

I’m surprised it never had the TSB for the leaf springs done.
I can’t answer your 10mm question.
But of all the places I actually have “real rust” so far, it’s the trailer hitch.
Not enough to compromise strength, but it’s there.

 

Enough that there's a 10mm hole in general is my understanding, not necessarily perfectly round. I have a 2010 and it got the first inspection/CRC applied last year, which gets me until Sept 2021 to get the second inspection.

I've heard at least one trouble spot seems to be near the catalytic converter..not sure if just one side or not.

There's a few good threads on this but I think this is the most succinct and started in 2017 so the most current stuff here IMO.

https://www.tacomaworld.com/threads/toyota-frame-rust-recall.508555/

 

Another decent read:

https://www.tacomaworld.com/threads/rust-prevention-treatment-consolidation-thread.355928/

 

Last one for now but it shows some good pics of the catalytic converter area I mentioned

https://www.tacomaworld.com/threads/frame-rust-inspection-and-brakes.516376/

 

Hopefully something can come from this inspection in regards to the leaf springs. I do have plans for some mods in regards to leafs/coils/wheels etc. but I’m wanting to spend time ironing out the kinks while it’s stock before I spend any effort on upgrades.

The trailer Hitch for me is a troublesome point as well, hopefully Toyota can assist with getting these couple of areas sorted out.

 

Thanks for the links! I don’t believe I have any holes, although it’s much easier for them to see on a hoist than me underneath on the ground. I suspected that was the case (a penetration/hole), so thanks for the clarification.

The inspection is tomorrow so I’ll see how it goes and update the thread with what they say. Appreciate the feedback!

 

Proactive Corrosion prevention is key to Tacoma frame lifespan.

 

I'll second that. I started doing FluidFilm once plus touch up every year after the frame swap. Hopefully this will keep the rust at bay at the tuck will die of other causes much later.

 

Appreciate the feedback and assistance, thank you! Like anyone, I’m just wanting to ensure my Tacoma is able to live the best life possible without (or at least minimal) issues such as rust.

 

Fluid Film is good stuff.
It can damage some types of foam.
So, I don’t let it get on any of the door seals.
Honestly I don’t really use it much on my truck

I mostly use it on my lawn equipment.
It supposed to be safe on all greenery.
So far I haven’t had any issues with it causing any damage to trees, shrubbery, or grass.

 

frame rust isnt bad really there. you can remove and sandblast that hitch assembly. paint it and put it back on there.

 

I am liking that idea.

 

Update: Upon the inspection from Toyota, they deemed the frame structurally sound (actually giving it a better report than I thought). I had a good chat with the service team member who was very helpful and overall, gave me some piece of mind. I appreciate the feedback on here as well which is always helpful!

 

Based on your pics, I see nothing at all concerning about your frame. Looks really good. Not surprised you got a good report. And the hitch looks normal too. Those exposed edges rust bad but the joints and hitch frame look good. No way to warranty the hitch unless it failed and it won't. Best you can do is grind the rust and touch it up with POR-15 and paint. Or just buy a new hitch on your own dime - which will look the same in 5 years.

 

Thanks for the feedback! This is my first Tacoma as I’ve only been in the U.S. a few years however I’ve owned multiple Hilux’s in Australia. I had some concern since reading a lot about the Tacoma frame issues, but glad to get the feedback from Toyota and others such as yourself. Cheers!

Fair enough on the tow hitch and on the warranty side of things - looks like I need to bust out the grinder and some POR-15/paint.