Rust Inside Frame

Yeah I don’t know if I’m confident enough to drill holes in the frame; wouldn’t want to compromise it anymore. Do any of y’all have experience with welding on fish plates or reinforcing with the safe-t-caps and the like? Seems like it would just cause it to fail elsewhere.

 

Unfortunately the inside of box sections have multiple obstructions.
Taco would look funny dragging that drain snake and drill

 

I've welded Safe T Caps over box sections. No problems caused elsewhere. It's possible to screw up any job though I suppose.

 

Yes there are some abstructions, one section at a time. I was able to look all through my frame with an auto endoscope to see what I was dealing with.

 

I know what you mean, my thought was to drill out the existing drain holes to about 1/4" or 3/8" at most. That is not enough to compromise the frame.

 

Not really Dana only built the Frame it was whoever made the steel and I have yet to ever hear who that was .

When Hauling Coils into GM or Ford the certification traveled with the coils.

Same thing with Butler or Morton Buildings.

Most often The end user Specs the steel the mill makes the steel .

The fact this problem has lasted this long is really strange.

 

Yeah I was kinda thinking since it's lasted so long maybe I'm in the clear since if it was going to fail it probably would've already. Then again, it could be on its last legs. Hard for anyone to say for sure.

 

I spray the inside of my "new" frame with 75W90 differential fluid, using the 360 degree sprayer from my Fluid Film kit. So far, so good. I'm not sold on Fluid Film, after having used it for a few years. I have also "painted" wheel bearing grease on most all of the panels that you can reach underneath. Maintenance is messy, but at least I have something to maintain!!!

 

Update: It's worse than I thought. I poked around inside the frame holes just in front of the rear wheel well and came up with some HUGE chunks. You could see the old paint on top.

I think I'll have to cut my losses at this point, as I don't see anything that'll save it at this point, at least nothing cost-effective. Amazingly, there's still no outward signs of any structural compromise, but I figure it's only a matter of time.

It's a shame these early Tacos came with such crappy frames; they're such scrappy trucks otherwise. What was wrong with the fully boxed frames from the earlier Pickups anyway?

In any case, I've learned a lesson about vehicle acquisition; any potential future purchases will be gone over with a fine-tooth comb, inside and out, especially older trucks like this! Pics below.

 

I’m there with ya my 2003 is a death trap lately. I’m currently looking for old thread I read once about rust free frames for sale from out west... I clicked on it back then so it did exist but can’t find it currently. Hope it is still out there, because it’s time to replace mine. I know I can do it but need frame to do it. I’ll keep looking but if anyone knows of it post it here.

 

Don't overlook:

https://www.autorust.com/product-category/toyota/tacoma-xtracab-4wd/

 

Don't overlook frames from the southeast too. I happened on a partout in central Florida that had a rust free frame. I didn't need it (post frame replacement), otherwise... It's now been sold. Kid selling didn't have any idea how valuable it was.

 

Think this may have been it...
https://automotix.net/usedautoparts/contact_us.html

For a few dollars more you can buy a new one... hard sell to a non-understanding wife though. Too bad these are frames without trans mount, bed mount and etc parts. Costs more for those little parts.
https://parts.lakelandtoyota.com/pr...lRange=0&ukey_driveline=6762&searchTerm=Frame

 

Read recently on another post that guy had a truck with a replaced frame that was now toast also... if I replace mine it’s gonna have to be treated and or altered to allow for easy clean up. Tempted to cut frame so that I can allow water to easily exit via gravity but add angled deflection so nothing can go directly up inside. Who knows but step one is to get alternate work vehicle up and running, and decent or new frame headed my way.

 

Yeah I think I'm still just gonna sell and look for a nice single cab with a clean frame down here in Arkansas. There has to be one out there!

 

My Boss had his truck up on a really big forklift today... messing with his transmission. I decided to look at frame since it was up in the air. Zero serious rust and it’s a 2000 Chevrolet S10. My truck is a 2003 Tacoma, wow I wish my frame was nice like that one. It’s all boxed in and has fewer drain holes than mine??? I’m thinking the coating or lack of one is Toyota’s big problem or metallurgy... sad!

 

Just found my first hole in the frame, I think right under where the AC drips onto it. Honestly, even when the frames on our trucks are in perfect condition, they're still flimsy and paper-thin. I really don't understand why Toyota did that; it's like they gave us the weak and watered-down version of the Hilux. I have enjoyed my truck, but I feel like I might as well have gotten a Land Rover or Nissan. Yes I know they're also a major PITA, but at least they have real frames under them that are less liable to disintegrate in front of your eyes as you pour money into the thing trying to keep it on the road! I only hope I haven't waited too long to cut my losses with this junk!

At least the top end end hasn't failed on me yet lol; i think the POs might have actually adjusted the valves on the 2.7!

And yes I know it's a 23 year old truck, but there's no excuse for frame rot like this in a truck where the rest if the undercarriage is actually in pretty good condition.

No disrespect to any first gen owners lol, just needed to vent a little.

 

Understandable... I’m ticked myself but really like truck and am looking to replace with new or Frankenstein a better manufacturers frame under my truck.

 

I really like the truck too but it'd be almost perfect with a beefier/more corrosion resistant frame under it. Sure, it might've added several hundred pounds, bit worth its weight in gold. It's the only thing turning me off from looking for another Taco.

I saw a clean single cab frame for sale in NC but I'm not sure it'd be cost/effective to take on he work involved in installing it..

 

Its really not hard to do with just basic home tools. This is how I did it.
https://www.tacomaworld.com/threads/the-green-truck-5lug-to-6lug-conversion.660999/