How to replace the rear cross sill

Thanks for the write up!

I'm about to tackle this project in a few days on my 3rd gen after having backed into a power pole while the tailgate was down due to being loaded up with a few dirt bikes (in my defense, it was dark and I had just driven 16 hours from Colorado to California, so I'm sure fatigue played a part, but honestly, a stupid move that should not have happened). Besides crushing the tailgate, it also bent the hinge/damper area on the passenger side of the cross sill. Fortunately, no other damage.

I saw on a YouTube vid that removing all the bed bolts (the T55 ones) allows the bed to be slid rearward enough to provide extra access to the bed panel bolts behind the cab. I'll likely completely remove both bed panels just to get them out of my way for removing/replacing the sill. Since the truck is only 4 years old and being in Colorado, I'm not anticipating any rust issues or having to grind off/drill out any bolts. I'll likely anti-seize the bed bolts when I reassemble, though.

 

I just did mine and found it easier to undo the bed completely and lift it up and off the trick, in order to slide the bed back you have to remove the rear bumper as well. And I was hoping to avoid this completely. The sill itself drops below the top of the bumper at the rear end making it harder to slide the old one out and new one in while still on the truck.

 

So, to keep from having to remove the bumper, you removed the bed entirely? Or did you still end up having to remove the bumper?

 

I did not have to remove the bumper, but you need 2 or three ppl to lift the truck bed up and over the bumper and gas tank neck, don't forget to take the gas cap off.

 

Got it. Thanks!

 

Glad to help gentlemen. @Beer:30 it should be easier with a newer truck. At 14 years old when I did mine (and prior PA salt exposure) nearly every bolt head broke off.

 

For the guys who have done the rear cross sill, is there a way to strengthen it?

I installed Total Chaos bed stiffeners on my Tacoma to prevent the weak rear cross sill piece from bending/ cracking. At the time I wondered if it would be possible to add some thick 3/8ths plate bent at 90* on the inside of the rear cross sill, weld it in or just drill and bolt it into the new rear cross sill.

 

Got 'er done...

 

I think you could bolt a 1-1/4" wide stiffener inside the tail light pocket in front of the wire harness opening. Welding might be possible, but the cross sill is only 18 GA (.048") CRS sheet, which might be tough to weld to something a lot thicker without burning thru.

 

I plan to replace my bed sill- it has damage on the pass side and was not fixed properly- Anyone have photos of a damaged sill from having a topper on the truck? I would like to know where they fail so I can reinforce that area on the new one.

 

I had to replace mine a while back due to a spare tire holder. They crack at the top where the metal bends, most bed stiffiners don't mold to that part of the sill but the total chaos ones do.

 

They fail near the top? at the red line?

 

The bottom corners failed from hauling wood, the bed stiffiners I got where the only ones that molded that curve at the top, but they all support the bottoms corners

 

Mine failed at both these points

 

Thanks,
I will look closely at my replacement bed sill and figure out how to reinforce those areas. Perhaps the external bed stiffener is easiest.

 

I got the bed off & damages bed sill off - I picked up the new one at toyota got the internet discount $525 or so ouch but better than $750. The new one is sheet metal with spot welds and some glue in a few spts.