Rusted Frame

Would love anyone's thoughts on how to proceed with Toyota! My 2003 Tacoma was brought into a dealership in 2016 to have the frame treated, the dealership said the frame was in great condition and chose not to do anything. 4 years later the truck failed an inspection for a rusted frame. I've spoken with Toyota a few times over the past couple of years and keep getting told the program is over. But had the dealership coated the frame in 2016, I think it would be in good shape. The Tacoma runs great, 180k miles, no other issues, just a toasted frame.

 

Hi Jon and welcome to TW! Sorry to hear about your situation. Could you add pictures of the bad rust areas of your frame? This will allow others to see it and give better advice.
Besides a full frame replacement, there are some patch kits to repair rusted out spots of the frame.
Hopefully someone with more experience with this will chime in.

-Tim

 

Not treating the frame after passing an inspection doesn’t sound like Toyota’s original policy per the Gen 1 enhanced frame warranty program. I thought it was either treat or replace the frame, not send someone on their way.

I’m on the road so not near my archive, but the pdf instructions for the dealer to use for that campaign (which was never an official recall BTW) can be found in this forum or elsewhere on line to double check.

Do you have the original records where the dealership noted their inspection results and their subsequent no-action?

That could be important in your discussions with Toyota.

 

Not trying to be pessimistic, but Toyota won't do anything for you. They don't dabble with frame repairs, only replacements, and no new 1st gen frames exist. Doubt they'll offer you any money for your troubles either.

You're just going to have to decide how much you love this truck, and if it's worth a large chunk of change to repair. Then you'll have to decide if a frame swap, or repairs to the existing frame is the correct course of action.

The most economical choice will likely be to sell the truck (either as a project for someone else, or part it out), and buy something that will pass inspection.

 

Couple of photos! You'll see it's pretty bad in some spots. I do think Toyota should be liable because they chose to do nothing, knowing it would rust out. Wasn't that the point of the settlement.

 

I would certainly be frustrated with the decision of the dealership at that time. Obviously things would've been better if you got a new frame. However, given the degree of rust on this frame, I doubt your second frame would've faired much better. You gotta keep an eye on these frames and coat them with oil or expect what you have :/

That said, post more pictures of the entire frame to see if it is possible to save. The parts you have shown are completely toast.

 

that is not possible to save. if that part is that bad, the rest of the frame is certainly compromised as well

 

The first photo of the frame by the spring hanger would explain why the gap between the bed and cab is larger at the bottom than the top. It's amazing that part of the frame is still together.



If the frame failed inspection in 2020, how have you been able to drive it for 4 years since?

 

It's stories like this that bring up the importance of checking your frame yourself. Friend had a 1st gen that " passed" inspection,he was skeptical and when he got home he crawled under his truck. Low and behold he found holes, Toyota ended up buying it back. To the OP you need a new frame or sell it for parts.

 

One bump and that truck is folding in half

 

Out of curiosity, how many years have you owned the truck


Toyota would be hard to go after......the dealership made the call...

and with that being 8 yrs ago.....





I think your only hope is to find another one that is front-end totaled.

And then swap....

There are so many of these......not as hard to find as it sounds...

there's probably a half dozen of them in Texas as we speak.
they drive like a bat out of hell....



You're gonna be fighting rust on that truck for the rest of its life, because of where you live.
You'll have to decide if its worth it.......as it gets older you have to swap out chassis parts.......it will be 'saws-all' city to get every bolt out eventually.....if not already.

All your fasteners are wasted.....reason you need the whole donor truck...
and at that you'd need to go scour, prime, and paint the new frame too...
and keep painting it every few years.....frames, inside and out.

 

Because I don't live in one of the states with harsh winters the 1st gen frame recall wasn't something I followed or kept up to speed on. Didn't it require owners to have the frame inspected and coated prior to a certain date (years before 2016?) to qualify for the 15 year warranty?

What was the coating, and how long did it actually last?

 

There are a lot of variables here: Where did the truck live for the first 13 years prior to 2016? The frame could have been perfect in 2016 if outside the salt zone. Hard to imagine that level or rust developing in 4 years, but 8 years (2016 to 2024) definitely possible. Where have you been driving the truck since 2016?

Toyota no longer makes frames for 1st gens. So even if you had a great lawyer you're not getting a frame. You could fight like mad and try to get a buyback, but that seems like a super long shot and you'll spend more in lawyers than the value of the truck. Toyota should have treated the frame per their policy in 2016 and that's your best argument. That said, the treatment was not a guarantee -- it only slows frame rot. Mine was treated in 2012 with an excellent Virginia frame, but 10 years in NY killed it and last year I had it patched.

It might be worth a few persistent calls to Toyota but I doubt it will result in much. I suggest rather than waste time fighting Toyota for what will likely amount to nothing, just repair it, or let it go. SafetyCap frame sleeves made in Rhode Island are your best bet. But what you have there is pretty bad and unsafe -- I would repair, or move on but don't drive it as is. Looks like the other side isn't much better... A couple $k in repairs might get you a few more years.

It's a super bummer. Mine has 170k and runs great. I'll keep mine one more year and likely move on.

 

Your only shot of getting a frame is not from toyota...

there a number of toyota dealerships along the very northern states that have a back stock of these frames...

they wont do warranty with them.......you pay for the frame and swap...

You can track these down.....but we're probably talking north of $8K altogether..

and that frame will rust just as fast if not faster than original....

So if not committed and take care of the new one....just wasting more money...


From the news there's a fresh crop of em in Texas in last 48hrs......from all the flooding....

 

ya take care of the frame baby it get it professionally coated wash it wipe it gold plate it no worries it'll still rust out ask me how I know

 

Depending on where you live......it may be a lost cause.

And even then the deadly rust starts inside out...

Even in a southern state I do the fluid film with the 2 foot spray straws inside the frame boxes once a year....


buy the straws online......wally world for the FF.


Just be happy you dont have 40K in a FJ that'll rust just as fast.....

 

I have an 03 SR5 2.7 4 cyl. 5 speed. Original owner living in NE US. Frame treated in 08? maybe but rusted out now, won't pass inspection. Has just under 65,000 miles. Interior is close to mint, A/C works, performed oil changes religiously, all around good condition minus hood/roof paint, damage to driver door and... frame. Don't have $ or time to swap out frame and all other rusted components or part it out. Was just wondering taco owners opinions on ball park numbers what I could look to get for it private sale as is? Ty