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2003 Tacoma frame rust repair

Discussion in '1st Gen. Tacomas (1995-2004)' started by BossFan, Dec 24, 2020.

  1. Dec 24, 2020 at 3:48 PM
    #1
    BossFan

    BossFan [OP] Well-Known Member

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    A couple months back I put a rear-view camera/mirror in my ‘03 XC. When I was running the wires along the frame rail, I noticed the the crossmember near where the rear shocks are was rusted through pretty bad. I ordered a new one from ToyotaAtlanta and it finally got here last week. I also ordered new bed bolts. I’m off from work next week and was going to remove the bed and do the crossmember swap, but I started thinking should I also replace anything else while I have the bed off? Gas tank straps? Fuel pump, study like that? Here’s what the crossmember rust looks like
    B512977B-FCD5-497A-9000-A9DD15FAE4E4.jpg



    I noticed that the rear driveshFt has rust in it? Should this be repaired/replaced?
    D0061885-B68A-4537-9936-D467163A97D0.jpg

    And lastly, in reading the ‘how to’ on removing the bed, it was suggested to drop the spare. How do you get the bar that holds the spare in place to turn? I’m assuming that’s how the spare comes down.
    33FAF5F6-1CB8-49A8-9F70-66440C71D461.jpg

    Thanks!

    New crossmember
    D21BEFE3-C804-4466-8864-649F585EAA3C.jpg
     

    Attached Files:

  2. Dec 24, 2020 at 3:52 PM
    #2
    TheFang

    TheFang No Big Deal

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    There should be a small window in your back bumper by the license plate. Through it you access the crank that lowers the spare. In your tire changing kit are the extensions used to crank it down.

    If you dont have a window, you access it in the crack between your rear bumper and the tailgate.
     
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  3. Dec 24, 2020 at 4:07 PM
    #3
    Black DOG Lila

    Black DOG Lila Well-Known Member

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    You should have a jack kit with folding crank that fits between middle of rear bumper and bottom of tailgate. The round end goes in there and into a slot above spare to crank down the spare.
    Looks like a good time to hammer test the frame for rust through. With bed off is time for needle gun, Coroseal and paint frame. Top with Fluid Film inside and outside of FrameIMG_20191008_145233266.jpg
     
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  4. Dec 24, 2020 at 4:08 PM
    #4
    0xDEADBEEF

    0xDEADBEEF Segmentation Fault (Core Dumped)

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    Rust, dents, miles, extra metal.
    You're going want to inspect everything under there with a hammer, there's gonna be more rust.


    Also how much did that cross member run ya?
     
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  5. Dec 24, 2020 at 4:11 PM
    #5
    BossFan

    BossFan [OP] Well-Known Member

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    Thanks everyone. This frame was replaced (original owner had it done by Toyota - I am second owner). Not that it matters. Just wanted to let you know that this wasn’t original frame.

    how do I hammer test? Is it literally tapping in frame with ball peen hammer?
     
  6. Dec 24, 2020 at 4:14 PM
    #6
    0xDEADBEEF

    0xDEADBEEF Segmentation Fault (Core Dumped)

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    Rust, dents, miles, extra metal.
    If you tap on a solid part, then a soft part, you should be able to hear difference. The rusted bits tend to sound dead and less ringy.

    Or you can break out the punch and see where it dents or goes through.
     
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  7. Dec 24, 2020 at 4:16 PM
    #7
    Black DOG Lila

    Black DOG Lila Well-Known Member

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    Yes, hit with ball. If it rings=good
    If it thuds =Bad
    Ball goes through= OH SHIT
    Shop here and buy a flux core MIG Welder.upload_2020-1-29_20-32-46.jpg
     
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  8. Dec 24, 2020 at 4:20 PM
    #8
    Black DOG Lila

    Black DOG Lila Well-Known Member

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    Replacement frames left untreated rusted as bad as original frames.
    Good luck
     
  9. Dec 24, 2020 at 5:24 PM
    #9
    BossFan

    BossFan [OP] Well-Known Member

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    Thanks everyone. I have a Millermatic MIG welder. Funny, I just posted over on the 1st Gen Bumper thread that I finally found a winch bumper I like, and was all set to pull the trigger, but now I’m wondering if I should wait until after I get the bed off the truck and do this hammer test. That bumper was going to run a little over $2000 but I may need that cash elsewhere. Ugh.
     
  10. Dec 24, 2020 at 5:48 PM
    #10
    Black DOG Lila

    Black DOG Lila Well-Known Member

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    Good plan :thumbsup:
    Rust out prone areas are passenger side rear shock mount, area by catalytic converter and fuel tank.

    IMG_20200419_111719027.jpg 2015-12-03 14.39.17_zpsfcezohib_7cb4c29fbd48c958e8ff26fbcc412b65c59ac690.jpg
     
    Last edited: Dec 24, 2020
  11. Dec 24, 2020 at 6:05 PM
    #11
    BossFan

    BossFan [OP] Well-Known Member

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    The crossmember was $240.
     
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  12. Dec 24, 2020 at 6:10 PM
    #12
    BossFan

    BossFan [OP] Well-Known Member

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    Ok thanks. What about the rust on the driveshaft. Is that a problem?
     
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  13. Dec 24, 2020 at 6:14 PM
    #13
    Black DOG Lila

    Black DOG Lila Well-Known Member

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    Wouldn't hurt to wire brush, convert rust with Coroseal and top coat with Rust-Oleum black farm enamel.
    If it's not causing vibrations now it should be ok, keep the Ujoints zerks lubed at oil changes.
     
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  14. Dec 24, 2020 at 6:18 PM
    #14
    Black DOG Lila

    Black DOG Lila Well-Known Member

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  15. Dec 24, 2020 at 6:19 PM
    #15
    MoreMonkey

    MoreMonkey Well-Known Member

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    Be ready to replace brake lines. The line running from the master cylinder to the load valve on my 2003 was crusty, and when I gave it a pass with a wire brush it started seeping brake fluid. It’s super easy to access when the bed is off. I also replaced the tank strap and shocks while my bed was off for rust repair.
     
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  16. Dec 24, 2020 at 6:43 PM
    #16
    BossFan

    BossFan [OP] Well-Known Member

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    Thanks. I definitely plan on keeping this truck. The wife makes fun of me because I like this truck so much. She thinks I should just get a new one.

    I replaced the shocks (with new Bilsteins) and the rear springs last summer. So I’m good there.
     
  17. Dec 24, 2020 at 6:52 PM
    #17
    Black DOG Lila

    Black DOG Lila Well-Known Member

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    I know the feeling well. I was told the same thing 10 years ago. I love my Taco more with each passing decade.
    The older they are the more they are worth and harder to part with.IMG_20191007_131834626.jpg
     
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  18. Dec 24, 2020 at 7:37 PM
    #18
    BossFan

    BossFan [OP] Well-Known Member

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  19. Dec 24, 2020 at 7:41 PM
    #19
    BossFan

    BossFan [OP] Well-Known Member

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    Nice. What topper is that?
     
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  20. Dec 24, 2020 at 7:51 PM
    #20
    Black DOG Lila

    Black DOG Lila Well-Known Member

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    It's a Century
    With locking side windoors to access shelved bins, sliding and lift open front, locking rear hatch.
    All dark smoked glass.
    $675 new in 2004
     
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