Frame Rust

Curious to see if anyone else out there has run into a similar problem as I have. I bought my truck mid October, I knew it was a NJ truck and had some frame rust but I also knew that it had recieved the undercoating and had the extended warranty. It was 6 hours away, but I couldn't find anything in my area like it for the asking price; 04 TRD 4x4 DC with 122k and a camper shell, in good condition and I bought it for $13.7k, which I felt was reasonable in the unreasonable world of used tacoma prices.

After test driving it and seeing it in person, I knew it would need a new suspension and tires soon, but for the price I got it at, I was OK with that. I had it inspected by toyota and the frame passed inspection, so my next step was to buy a suspension, and I decided on the OME kit. That brings us to this week.

Monday night I took off my front struts, and then on Tuesday morning took the old struts with the new parts and had a local offroad shop assemble the new struts for me. Got the new struts installed shortly after and went to work on the rear. After jacking the truck up and having sprayed everything multiple times with PB blaster I started with removing the rear shocks. Only problem was, they wouldn't budge. After repeated beating with a hammer and no luck, I was able to remove the driver side shock with a sledgehammer. The passenger side wouldn't even come off with the sledge and was close to snapping inhalf. So, I called the offroad shop back, and they gave me a quote on doing the rear suspension, new tires and an alignment. I was ok with everything, and decided it was best with my time constaints to take it in to them.

So yesterday afternoon I called to check on the progress. Turns out they had to cut EVERY bolt out, and they had to cut my front rear leaf mounts OFF and fab up and weld on new ones due to how bad the rust was. Then during the alignment, they broke the cam bushings on the passenger side, and now I need a new LCA and bushings so they can finish the alignment.

So basically, after getting a reasonable deal, I'm in the hole more than I'd like to admit, but I'm hopeful that my truck is good to go for awhile. I'm just amazed that my truck passed inspection by Toyota, and then was so seized up from rust that the above happened.

Anybody else dealt with this or something like it?

 

The Toyota inspection is for frame integrity. It's absolutely possible to have stuff rusted up with the frame being solid. When I did rear leafs on my 98 Tacoma (NH truck - this was back in 2006 or 2007) I had to cut the shackle bolts - surprised the mounts had to be replaced, though.

 

I understand that it's integrity they are looking at. I guess I'm more suprised by the fact that they didn't warn me as to just how bad the bolts were likely to be when I mentioned replacing my suspension. At least I found an honest shop with reasonable prices, I'd hate to think of what the local dealer would have charged me for this work.

 

There is no way of knowing if suspension bolts are frozen until you put a wrench on them.
My front adjustment cams were frozen, 3 out of 4. Still are, left them as is.
My rear suspension, had to cut one bolt only, the one by the gas tank that can't be beat on. The rest came out fairly easy with the help of a 2 pound sledge.
Congrats on the new ride.

 

Just brought my Tacoma in for a front end alignment two days ago. I knew that an alignment was attempted 4 years previous and the cam bolts were frozen, rusted. Its a well known problem with these vehicles. I talked to my local mechanic and he said most people don't know how to free rusted bolts. He said he heats them up with a propane torch and then sprays them with a squirt bottle of water. That breaks the rust bond between metals. I watched him do it on another customers vehicle. So i made an appointment and in the meantime sprayed the cam bolts with a mixture of WD-40 and Diet Pepsi. Did that for 3 weeks every other day. When the mechanic went to turn them he had no problems and didn't have to heat them up.

edit
Pb Blaster or Diet Coke would work just as well. The reason for the diet instead of the Regular is because of the sticky sugar..

 

Interesting, I may try this. Thanks for posting that info!