Frame rust question follow up 2009

So I got my 09' on a lift to better inspect the frame. Looks like there is one bad part of it. Wondering if this is a serious issue? I'm not super familiar with parts of the truck, still learning even though I've had it for 10 years. I've pretty much just taken it to the dealership for oil changes and done what they recommend (which has probably cost me a grand in unnecessary things, but I'm learning). Is this one of the rust prone areas? The other side in this same spot looks good. the back of the frame also looks good on the inside-the very rear under the bumper had a lot of surface rust i wire brushed but no holes. are there any really hard to see rust prone spots that might be hiding from me?

I wire brushed any rust while it was on the lift and then fluid filmed the frame with an undercoating gun and 360 degree attachment. Unfortunately, wool wax isn't available in Hawaii to avoid the smell so fluid film it is. When I wire brushed this one part of the frame on the passenger side front, A LOT of the rust flaked off and now there is a hole, you can see in the second and third pic where it flaked off. I'm not sure what part this is called. I had to undercoat it without a lift (wasn't allowed) so I didn't have as good of a visual that I got everything but plan on taking it back on base to lift it again and check I got everything.

Thanks for any info, after seeing the prices of the new gen, I've decided to keep my truck til it dies and don't want to lose it to rust.

 

Yes, you have a hole in one of the most common failure spots - the boxed section near the catalytic converters. (Second picture, top / right corner.) No undercoating / Fluid Film / etc. is going to replace the section that is now missing. (The rest of the frame looks pretty darn decent though.) You need a good welder / fabricator to look at it.

 

Weird the frame looks pretty good but there’s a hole by the weld

 

There is a hole there because that is on the passenger side, right under/behind where the condensate drain from the HVAC system is, and right nest to the catalytic converter.

I don't understand why more people don't extend their condensate drain with a 12" long piece of 3/8"ID clear tube. It takes about 5 minutes, and prevents rust in this area. Once the rust starts, however, it is too late.

 

Well the biggest hole is in that square portion. Before I put the wire brush in there, I took a pic (first pic). Then I stuck my hand in there and started brushing and a bunch started flaking off a lot in that section (2nd and 3rd pic). There is also the small hole in the upper right. There's nothing like that on the rest of the frame which is good

As for extending the drain, I think there are a lot of people like me who just drive their truck and take it to the dealer every 5000 miles and get it serviced. Obviously, I learned some lessons! I also had peace of mind with the frame because my first dealer told me my frame warranty was extended until 2030 and sent me the screenshot of it, so I was like, oh great, I'm covered. I even asked them if I should fluid film it in 2020 when I first noticed the rust, and they said don't because that will void the warranty. Then when I went for my yearly free inspection, they told me it had changed for some reason and I was no longer covered and sent me another screenshot and said I'd have to ask Toyota about why it changed...and they have not gotten back to me

I'll look into a welder, thanks for the suggestion

 

This would've failed threshold stated in the frame campaign instructions (holes larger than 10mm).

Grind away the rust as much as you can, then weld in a Safe-T-Cap: https://www.autorust.com/product/front-frame-section-tac-230x-d-r-passenger-side/

 

thanks for the link. Also, i finally figured out how to reply directly to someone hah! So this looks like the piece that has the small hole. What do I do about the large hole in the square portion of the frame? would that be a separate piece?

 

thanks, i'm reaching out to a few locally now that have rust restoration on their websites. Do you know if these welding repairs are a permanent fix if I keep it fluid filmed? Or would they need to be redone periodically? One website says "Our temporary rust repair patches last 1-2 years. We’re happy to provide a ballpark estimate after seeing photos of the rust repair project, and we’ll get you an exact quote after seeing the project in person. (Given the way metal corrosion often hides out of sight, we do patches but not full rust removal and restoration, which this is rarely cost-efficient for the client.)" wondering if that's the standard or if I order the replacement parts listed below if they can weld those in for a permanent fix. I'm going to ask them too, but I've found that by asking the dealer questions at least, they seem to take advantage of the fact that I'm not knowledgeable-like my unnecessary left valve cover replacement and rear transmission output seal replacement because of "leaks" that will cause "a lot of problems"

 

Carefully cut off the crossmember mount, plate over the hole, then weld the crossmember mount back in. It's a lot of work.

Come to think of it, since the rest of the frame appears to be in good condition, you don't need the Safe-T-Cap piece. Just make the plate bigger.

 

I have an 09 as well, it’s lived its whole life in dry New Mexico, I think after reading this I’m going to need to check my frame especially near where the AC drain hose is

 

I bet it's fine in New Mexico, good to check though. I think it was 4 years in northern Virginia with brine on the roads that did it to my truck, and I guess not extending the AC drain! Plus, complacency on my part after the dealer told me it was covered until 2030 and sent me the warranty screenshot. I was thinking, wow, plenty of time if it rusts through. Costco alerted me to the issue on my last tire rotation and I called the dealership to get my free inspection done since it had been a couple years and that's when I found out it was no longer covered, and they don't know why their online system changed the date.

 

FWIW, I had my 2014's frame initially inspected for the frame warranty extension program in 2021 soon after I purchased it. The frame was plugged and treated with the corrosion resistance compound on the laminated portions and in the boxed sections on the first inspection. They advised me to come in every year for an annual inspection, which I have done. It is warranted until 2026 (12 years).

I have personally touched up/painted the welds and applied Fluid-Film every fall since and they haven't said a word about it voiding the Toyota Frame warranty.