Frame Rust - How Screwed am I?

I have a 2003 Extra-Cab TRD Off Road that I bought used in 2005 with 19k on the odometer. It has treated me well over the years and has over 230k on it now.

It failed inspection yesterday for a muffler, which is simple enough to get fixed, but the inspection station mentioned the frame near the front of the passenger side leaf spring was rusting.

I got under it this morning and hit it with a hammer to see how bad it was. It still sounds pretty solid except in one small spot. It looks like the muffler leak helped the problem along quite a bit.

I know this is common and there are a ton of threads on what you can do to it, but I wanted to get an idea of just how bad folks that have seen the problem before think it is. I'm not interested in trying to fix the issue. The truck already needs a new timing belt and new clutch, which won't be a big deal if the frame is ok but, if this needs treated, cleaned, repaired, capped, etc., I'll probably just get rid of it.

I've been looking at new trucks for a few years now (wife can't drive a stick, and I have a kid so extra-cab doesn't work well with the family), but have never had a reason to pull the trigger since the 03 has been so reliable and just worked, but I don't want to sink a ton of money into a truck that is a daily driver I've gotten my monies worth out of. I live in the WV/VA/MD area, so we get some snow and they treat the roads which doesn't help the situation.

Thanks for any input!

 

That doesn't look that bad. You said it still sounds solid when hit with a hammer, that is a good test.

It will eventually fail, but you can slow it down by coating it with Fluid Film or something similar.

I've had 2 Tacomas fail on my from frame rust. There was no question they were done for. Yours looks pristine compared to what mine looked like.

 

Welcome aboard. Replace the muffler. Get a new Va.inspection sticker, if the frame passes sell it.

 

welcome to TW

 

wow, how bad was yours?
i am totally whiggin out on mine for the past year now after seeing pics on TW and then hitting the salvage lots finding local trucks just collapsed
finally got a borescope camera to check on the innards to see what the heck is going on where all this peeling paint coating coming from to seal it up thoroughly but good

 

compare to others:
https://www.tacomaworld.com/threads/rust-prevention-treatment-consolidation-thread.355928/

 

Both of mine rusted thru at the spring hanger. I welded in patch panels and drove it for 2 more years. One is still driven presently.

I Fluid Film mine every year or so.

It does help that I'm a metal fabricator and have a lift.

 

so you never had this type of problem?
this 96 truck originated in Michigan and ended up in western Iowa (160k miles or so)

 

Thanks for the input folks. I appreciate it. I ordered a new muffler and will put it on tomorrow and keep it for awhile longer.

 

Currently looking for a boroscope camera to check my inner frame. Can you recommend yours? Sorry for the thread jack.

 

Before it keeps getting worse let someone patch it up and get it back looking decent and add some strength to it.I say keep it till she won’t go no more

 

A shame The OP does not want to go the extra Mile and save the Truck If your in the Liquid Brine Belt depending on the rest of this winter and next spring 2012 parts truck for sale.

 

Looks like you have two projects.
Frame rust removal, treat and paint (wax or oil)
Muffler replacement

This is good time to check on the gas tank cross member and that strap and pins used to hold it up.

I had a full tank of gas supported by 2 bolts on the pass side and the exhaust had was providing some support. Everything else had quietly rusted away.

 

Was this your Taco?

 

Corroseal Water-Based Rust Converter Metal Primer, Rust Converter - 1 Gal

$73 Water-Based Rust Converter Metal Primer, Rust Converter - 1 Gallon

https://www.amazon.com/dp/B001CRETZW/ref=cm_sw_r_cp_tai_PVTuEbWPFVN0K

Used this on my T4R and Taco with a 5 gal backpack sprayer for more pressure and paint brushed the frame afterwards. The sprayer let’s you get back into the hard to reach places and I had an assortment of paint brushes from round small to wide as the frame rails sized and worked great...The warmer it was the better it worked I was in a warm garage after one attempt as it’s kinda thick SAE 30w oil like and in hindsite I should’ve used a paint sprayer with air, also I would wire brush the entire frame before hand as well...1 gal will do 2 Taco size vehicles.

 

Corroseal is without a doubt THE best rust converter. Converts Iron oxide (rust) to inert Magnetite

 

Also cleans up with soap and water, BUT don’t get it on your skin it’s like black dye and a PITA to get off I used latex gloves and a couple places on my wrist where got a few drops on was a Pain to get off.

 

no, just a local one that i found in a salvage yard

 

I'm gonna have to get me a jug of that stuff.