2006 Frame Rust Help

Hello TacomaWorld folks - I'm feeling in dire straits about my 06' taco with it's rusted frame and am looking for a little guidance.

Backstory: Bought my 2006 Access Cab V6 TRD in 2013 in Washington state (I am 2nd owner) but apparently it originally lived in Maine for a few years. Bought it with the intent of driving the wheels off of it due to Toyota's legendary durability and it has lived a happy life on paved and dirt roads exclusively around the mountain west since then (MT, ID, WA, WY, UT, CO). I'd noticed significant surface rust on the frame before the TSB Frame Rust program started and had it inspected in 2015... then again for in accordance with the TSB in 2018 at our only local dealership (Kalispell Toyota). It was also double checked when the truck went in for TSB leaf spring replacement. Each time it passed although I was a bit skeptical about the most recent 2018 "passing." Since Montana is not considered a "cold climate" state, no frame rust protection was applied by Toyota either time.

Current: I hadn't been under the truck much for the past couple years due to cranking (head in a hole) through grad school and but wasn't too worried since Toyota "passed" the frame in 2018. Last week I went to replace the well-loved original suspension (thank you Headstrong for the sweet 2" lift - it rides like a dream now!), only to find tremendous growth in rust throughout the frame. Specifically, the front body mounts opened up large holes with the slightest touch of a hammer (photos)... and I've got another substantial growth of rust along the frame rail near the passenger catalytic converter. My mechanic buddy who was helping me with the lift wouldn't let me drive home without welding some plate steel to the body mounts to ensure it wouldn't break on the way home... but doesn't want me banking on those for the long haul.







I immediately scheduled a frame inspection with Kalispell Toyota and (this morning) was told that the easily frame failed the inspection (10mm hole test). Toyota quickly stated that my coverage ended September 2019 and estimated ~$20k for a frame replacement. It looks like my truck would still be covered through 2021 if I lived an hour north in Canada (15 year coverage vs 12 in the USA)...

My questions for you folks are:
1. Could those holes have really only formed in 3 years? Or did Toyota miss something in my 2018 inspection...
2. Is skipping the frame rust prevention coating during the original inspections an obvious lapse in service from Toyota?
3. Are there any actions folks on here have taken to successfully have Toyota replace the frame outside of the current timeline?
4. Can the body mounts be replaced and frame reinforced so that I can keep using the truck for outdoor adventures/towing/wood runs/the reason I bought it...?

I couldn't be more disappointed in Toyota's response so far because 15 years is ridiculously short for the lifetime of a truck frame.

Thank you again for your support and commentary,

 

Hello friend. I have chased this problem exhaustively myself and I can assure you that Toyota will absolutely not take any responsibility for this.

Toyota will blame the dealership(s) who didn't or who incorrectly applied the CRC (anti-rust) treatments, the dealers will put in "requests" to Toyota, Toyota will deny them because you are outside the window.

It is frustrating or perhaps infuriating, but you are on your own.

You may look into a Saf-T-Cap (2nd gen Tacoma kits are available but possibly not on their website yet) and having some replacement body mounts fabbed and welded in place of the current ones.

 

Are you sure it's 12 and not 15 years here in the US? I thought it was 15. Regardless even if it is, yours is at 15 years this year and depending on the manufactured date of your truck it may have lapsed anyway. May be worth double checking this though

Sorry you have to deal with this.

 

Looks like they do have it on the website.

https://www.autorust.com/product-category/toyota/tacoma-2005-2015-2nd-gen/

 

My frame has broken from rust. Also has other bad spots. Dealership referred me to corporate, corporate had dealership call back even though truck was brought in while recall was active. Can’t get anywhere from toyota. Not even having luck finding a salvage frame for any kind of a decent price to attempt replacement myself. Sucks to have such an expensive yard ornament but have too much in it to send to scrap.

 

Thanks for the replies and it's real bummer to hear that deanosaurus. I'll aim to track down a local fabricator to see what we can do about creating and replacing my body mounts. Thanks also for the Safe-T-Cap pointer - those look like they could help beef up the rusted sections of frame...

Can't believe the real weak link of these "bombproof" trucks is the frame and that Toyota drew the line at 15 years. Nothing like creating absurd amounts of waste out of perfectly functional vehicles.

 

In the US it’s 12yrs since the manufacture date. So he’s outside his window.

 

It hurts my soul seeing post like this. I suppose in theory if you can get the frame/body mount repair parts from that website and find a decent welder/ fabricator you might be able to save your truck for a couple grand depending on labor... not sure though but its probably still much cheaper then getting a new truck although you shouldn't have to be going through this at all it really sucks.

 

@zachary miller did you end up getting a fix for your tacoma frame?
Mine looks really similar with the amount of rust, just took it to a metal shop and they don't even want to try work on it, quoted 10-12k! Such a bad situation to be in with no good solution!

 

Thats too far gone for repair unless you spend some huge coin. It would prob be cheaper to buy a frame then to try and rehab your current one.

 

@Josharoooo ooooofdah that looks rough. I had zero luck at Toyota but was offered a $15k frame swap from the dealership... I ended up calling around to all the body shops and getting distinct "NO" answers until one of them pointed me to a local fabricator who'd probably help me. He is a real friendly fella and, after looking at it, said "no problem - I've done a few of these Tacomas and it's a real shame the way Toyota treats their customers about this." He previously fabricated custom chassis for 20 years before branching into his own hot-rod shop and exclusively works on cash... which seemed about a perfect fit for my needs.

He ended up chopping most of the driver's side body mount off and fabricating a new body mount for that side. He was strictly of the opinion you don't fix something that still works so he only replaced my driver's side mount and told me to swing back by next year to take another peek at the passenger mount. $350 out the door and a new friend in the fabrication business has me feeling quite lucky to have found the backwoods expertise to keep my taco rolling long-term.

New mount:

 

When you put larger tires up at 285s you need to do a front body mount relocation so several make them such as :
2005-2021 Tacoma Body Mount Relocation Kit (tacomabeast.com)
Old one gets cut off and new new welded on if you frame behind it is still OK.
Tacomas hold water and junk in those mounts so they rust out with the AC drain dumping on the passenger side also. After my frame inspection that said OK and 12 years came and went I found that mount a mess of rust also so drilled out the lower holes and one in the wheel well lower mount to frame area and sprayed heavy Rustoleum paint in there.
The main long runs under the doors flakes apart on the lower inside so scape and paint/coat those. I keep up with the whole underside yearly. Eastwood makes an inside frame coating in a spray can with a 2' hose and wide spray tip to get inside. Sucks but Toyota will not help and those dealer inspections were a big waste for many owners. You need to do it yourself with a heavy screwdrivers and poke away at the frame because they sure don't.

 

Man, I can't "LIKE" this enough. Glad you found someone to help you out. Definitely stay in touch with this dude.