Bitten by the frame rust - 2009 Double Cab

Took my 09 in today for state inspection (PA) and mount/balance 4 new tires/alignment and they said they would also be inspecting the frame for rust damage as part of a program. Didn't think much of it as the truck is garaged and the frame looked ok to me. I change my own oil and do my own brakes, so I see it regularly. 30 mins later they're telling me a rental is on the way, and they're keeping the truck to replace the frame. I asked to see it, and they were kind of enough to let me in the back to take a look while it was still on the lift. Sure enough, rotted right through even though the surface rust on the rest of the frame is very minimal! Couldn't believe it, and couldn't believe I hadn't seen it:

http://gallery.netmagi.com/d/14234-1/09_frame_rust.jpg





Was told 4-6 weeks total, and they asked if there was anything else I wanted replaced, as the labor would essentially be "free" if it was just something they were taking off and putting back on anyway.

I put 5100's on it a year into ownership (so 8 yrs ago now?). Wondering if I should swap the shocks all around for new. Have been really happy with the 5100's. They still a thing? Something else better now? Anything else I should be thinking about?

Thanks in advance!

 

Might want to ask them what is covered in the swap and what isn't. Some dudes on TW have stated they have been charged for parts during replacement, somewhere on here there is a whole thread related to this issue. I would check it out if I was in your situation.

 

Skimmed some of those posts while still at the dealership, but they said "everything was covered". The truck has 96k on it and is genuinely in good shape and well maintained. Bought it new from this dealership and have had other service like wheel bearings, plugs and tires done there before. They haven't let me down yet.

 

Any idea why the rust would be clear through in that specific spot and so minimal on the rest of the frame? Is there something stamped in that spot as new, or where there smaller holes there originally?

 

If it were my truck I would be redoing the whole suspension. New coilover, leaf packs the works.

 

They rust from the inside out and heat accelerates the process...note the cat nearby

 

thanks! that makes a lot of sense

 

Make sure you check the rear bumper support and rear cross sill. Salt beats the living shit out of them. Mine was from PA, got the frame recall and these were NOT replaced. They were so bad you could push your finger through them. I replaced them on my own so it didn't spread. Wrote a few threads on it.

https://www.tacomaworld.com/threads/process-to-replace-rusted-rear-bumper-support-with-pics.549906/

https://www.tacomaworld.com/threads/how-to-replace-the-rear-cross-sill.553664/

 

Leafs in the back are only 2-3 yrs old due to the recall on those (and are the heavier duty variant). Any specific coilovers/shocks you recommend?

 

the frame is actually two layers of laminated steel there, salt/water gets trapped in there and rusts it out in a hurry.

 

Are they Toyota leafs?
Toyota doesn’t make heavy duty leafs.

It depends if you want a lift or not. If you don’t want a lift go with stock coilovers. If you want a lift it depends on what you do with the truck.

 

Toyota leafs. There's two sets of leafs available, the std. ones and the TSB leafs that are heavier duty. I've had 2 sets of each. Not looking for a lift. It sits ~3/4 over stock with the 5100's and the TSB leafs and happy with the stance and how it rides.

 

The TSBs are just a 4 leaf rather than a 3. I would not call them heavier duty. 4 flat leafs are the same as 3 flat leafs.

If you like everything keep it just go with stock replacements and new 5100s.
Suspensions are wear items and labor to replace is expensive. I would take advantage of the free labor as much as possible.

I replace struts every 100k and total suspension (ie coils and leafs) every 200k.

By the way what do you like about the 5100s compared to stock.
I would like to get a set but am worried it going to make the ride softer and I don’t want that.

 

Mine is rusted in the exact same spot.

 

You just seeing it now? Wonder if a screwdriver would go through there. Dealership didn't seem to be surprised by the location on mine.

 

My car spent the first 2.5 years of its life in Hollywood, FL near the beach. Doesn't seem to have any rust now or when I got it. It's a GA car now. Should I be worried about the 2 years it spend at the beach or probably nothing to worry about? Purchased it as a Certified pre owned from Toyota so the frame may have been coated or painted previous to me buying it.

 

I didn't see it till this past october . The rest of the frame looks pretty good.

 

Jigheadworm that is a hole on its way its just a matter of time. Find out how much time you have for replacement eligibility. That rust is sandwiched between the metal can't get to it. That's exactly how mine started. Good luck

 

I have till 3/21/2021

 

That is exactly what I did on my 2007 Sport's new frame swap. Runs as good as the 2018 loaner I had for 6 weeks.