Cracked Frame Sway Bar Link Mount

22 Tacoma TRD OffRoad 4x4 Double Cab. I was having my Icon 2.5 Coil over shocks replaced with some King 2.5 extended travel lift with reservoirs at a national 4x4 shop when they informed me that my Frame was cracked at the sway bar link mount. I took it to Toyota as I am the original owner and they determined it was due to outside influence resulting from aftermarket modifications which negated any warranty coverage. Only solution is to spend a lot of $ and buy a new frame. We have not done any crazy off roading pretty much limited to fire roads. There is a lot of welding splatter and some rust. I find it hard to believe that what I did caused the crack on a steel frame. I have scoured the internet and haven't found any mention of a crack like this nor have any of the professionals I have spoken to ever heard of this happening. I am appealing this at Toyota but don’t hold out much hope. Has anybody else ever seen this? Given Toyotas poor history of rust and welding splatter I think it could be a structural issue.

 

Not common and all I can imagine is that it wasn't torqued properly.

I'd toss the sway bar and move on with my life. It's not ideal and can fail state/provincial inspections but you don't NEED a front sway bar, and it usually performs better offroad/off pavement.

 

That's a really weird place to break.

Looks like either a hard hit that tweaked the hell out of the sway bar, or someone ugga-duggered the shit out of it with an impact driver during suspension install.

 

That looks repairable, without replacing the frame.

 

Absolutely!

There are many hoes on the frame rails bigger than that, not even close to hinder the structural integrity.

Any competent fabricator can repair this with a die grinder and Tig welder, makes stronger than new.

Cut out, bevel, tack and weld.