Frame Rust Root Cause At The Supplier

Thanks for the advise and once it warms up here I will coat the bottom of my truck with this stuff.

 

Rust Cure Formula 3000 at Crappy Tire

 

All I know is I crawled underneath the 2012 after a year and there was a lot of dirt and robin egg sized rocks in the boxed area of the frame. I took the hose and gave it a good flushing trying to get most of it out to the rear where the frame opens to C channel, there was a lot of dirt came out. There was some good sized rocks and plenty of gravel came out also.

 

A couple pounds of silt comes out of the little cab mount box up behind the front wheel every time I rinse my frame too

 

This is a little off topic but you guys sound like you can help. Took delivery of my 2015 DCSB on 6 Feb. Have been scanning the postings about DIY undercoating. I had a dealer installed back up sensor system installed. While crawling around under the truck I discovered that the cable to the rear sensors comes out an access hole in the floor of the truck. You can look up into the hole (about 2" across) and see the floor insulation.
Can I simply seal this with good silicone caulk or is there a better way to fill in this hole? I'm concerned about moisture that may be trapped once it is sealed up.

 

I disagree.... why?

Because Toyota never had these 'frame rust' issues prior to the Tacoma. Those older trucks were TANKS and some of them are still on the road 30 years later.

When I buy a truck or any vehicle, I shouldn't have to worry about needing to do anything to the frame or chassis on a regular basis other than cleaning. If I need to maintain a frame or chassis - then the manufacturer is slacking in its quality department.

That's just it..... EVERYTHING is slacking in quality these days. It's a damn shame.

 

It's definitely a worse-than-normal situation. I had an old 1980s Ford that lived it's whole life in the midwest, had rust holes in the rear fenders you could fit a baseball through. Hell, even the gas tank started to leak a little due to rust, but the frame was solid. Not even the slightest hint of a hole developing.

 

I have an 01 I bought new, and still own it. I took it in for its frame inspection convinced I wouldn't have a rust problem with it. I had washed it regularly, it didn't show any visible signs of rust, hell 95% of the frame paint was intact. It was bad. The boxed area, behind the front tires is where it failed. All of the frame paint was intact in that area, it looked perfect there. I asked the dealer to show me, to prove it. They sent me back with their best frame tech who promptly sunk a hammer right through the frame in that spot. . They replaced the frame about 10 weeks later at a cost to Toyota of just under $12,000. No problems with it since, and a 20 yr warranty. As upset as I was I have to say Toyota did take care of it.
I asked them if there was anything I could have done to prevent it... They said no. They said it was caused by a failure in the anti-rust treatment process. That was in 2011. They did say that "that" problem had been corrected, FWIW.

 

The mystery deepens. Dealer claims its not their wires from the back up sensors. They will put a grommet in the hole to seal it, But, the wire goes to a box about 4 by 4 inches perhaps an inch
high UNDER the carpet at the front left of the driver's seat. Without
taking out the seat, I can't tell what the cable goes to. Anybody
who has removed seats and carpet have any idea what the box may be?
Appreciate the knowledge base here.

 

I know my 13 frame has a slick feel to it compared to the bare metal of my 08. It seems like a sort of light coating from the factory, and no it isn't a spray on.