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Large cracks in transmission crossmember

Discussion in '2nd Gen. Tacomas (2005-2015)' started by MonkeyProof, Dec 7, 2011.

  1. Dec 7, 2011 at 8:17 PM
    #1
    MonkeyProof

    MonkeyProof [OP] Power Top

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    HBMurphy had mentioned his transmission crossmember being cracked so I went ahead and inspected mine.

    I found 3 large cracks and one small crack in the crossmember, I think it's time to replace before the cracks lead to a catastrophic failure.

    Driverside front of crossmember:
    [​IMG]
    Driverside back of crossmember:
    [​IMG]
    Passenger side front of crossmember:
    [​IMG]




    The bottom of my support brackets for the crossmember and the crossmember itself were pretty beat up from previous rockcrawling adventures. Looking at the condition, I felt some remorse and love all at the same time, knowing what we have been through. Poor thing lol.

    Passenger side:
    [​IMG]

    Driverside:
    [​IMG]




    There was some excess material that had to be removed from the crossmember support bracket that was trying to wrap itself around the cross member. Without removing that excess there would have be no way to remove the crossmember. I used a mini sander and a mini cutoff wheel; air tools FTW!
    [​IMG]
    [​IMG]

    It's obvious that Toyota has changed the design a bit. Here's a comparison between the old and new crossmembers. The new version is fully boxed from end to end. Also, there is a continuous bead of weld from end to end on the front side which was not present on the old style.
    [​IMG]
     
    scocar and Crom like this.
  2. Dec 7, 2011 at 8:43 PM
    #2
    SiRMarlon

    SiRMarlon The Photo Ninja!

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    Damm that is crazy Tom...but when you think about it. You have beat the shit out of that truck! :D
     
  3. Dec 7, 2011 at 8:44 PM
    #3
    Yoytoda

    Yoytoda The Little Truck That Could

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    damn! By the looks of it, toyota realized theres a flaw in the original desing. im curious to soo what my 2010's looks like

    :popcorn:
     
  4. Dec 7, 2011 at 8:45 PM
    #4
    ETaco23

    ETaco23 Marshall offroad Fabrication

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    Thats Crazy! what causes this to happen? Hard wheeling?
    Or is it just a defective part?

    Pics with it installed? :)
     
  5. Dec 7, 2011 at 8:47 PM
    #5
    jandrews

    jandrews Carolina Alliance Southwest Region Ambassador

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    FWIW, the crossmember design changed in 2009. It caused a little hell and we had to do a little crossmember modifying with a plasma cutter to get my skid plates to install.

    On the plus side, it looks like I've dodged the crack bullet.

    Continued shitty Dana frame designs, followed by revisions after durability QA.
     
  6. Dec 7, 2011 at 8:47 PM
    #6
    colinb17

    colinb17 If at first you don't succeed, don't try skydiving

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    ugh, now i have to go check mine tomorrow. and it's coverd by a skid plate which is gonna be a pita.

    do you have any idea what year they changed the crossmember design? i know mine's the old style, jsut curious what year truck to look for to yank one off of.

    Edit: question answered before it was asked. appreciate sir andrews.
     
  7. Dec 7, 2011 at 8:57 PM
    #7
    HBMurphy

    HBMurphy Ban Pending

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    Nice Job Tom!!! I still need to do something about mine. :)
     
  8. Dec 7, 2011 at 9:01 PM
    #8
    maxamillion2345

    maxamillion2345 Go home if you don't like guns liquor and whores.

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    Too many
    drill weld plate ?
     
  9. Dec 7, 2011 at 9:02 PM
    #9
    HBMurphy

    HBMurphy Ban Pending

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    I think the new cross member looks better! :) lol :D
     
  10. Dec 7, 2011 at 9:04 PM
    #10
    KenLyns

    KenLyns Lord of War

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    All current Toyota ladder frames (2nd Gen. Taco, 4Runner, Tundra...) are designed by Hino, which makes commercial trucks but has little off-road experience.

    At least Toyota is making the revisions. Other companies (except for maybe Jeep) would probably relegate this to "off-pavement abuse" and never bother with it.
     
  11. Dec 7, 2011 at 9:04 PM
    #11
    HBMurphy

    HBMurphy Ban Pending

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    I've felt that!!! :)
     
  12. Dec 7, 2011 at 9:06 PM
    #12
    HBMurphy

    HBMurphy Ban Pending

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    Too bad the bottoms of our trucks don't look like the 2012 baja race truck...

    [​IMG]
     
  13. Dec 7, 2011 at 9:33 PM
    #13
    MonkeyProof

    MonkeyProof [OP] Power Top

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    i think the main reason is a poor design. but my wheeling habits played a role into the cracks as well.

    on the old cross member you can see the cracks started at the beginning of each weld bead. i think that created a stress riser. plus, the cross member was not fully boxed from end to end.




    [​IMG]
     
  14. Dec 7, 2011 at 9:37 PM
    #14
    MonkeyProof

    MonkeyProof [OP] Power Top

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    after seeing it i didn't even bother to think about adding gussets like i had planned
     
  15. Dec 8, 2011 at 3:33 AM
    #15
    DDD

    DDD Shine bright like a hymen

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    So how much does a new crossmember cost?
     
  16. Dec 8, 2011 at 3:55 AM
    #16
    T@co_Pr3runn3r

    T@co_Pr3runn3r XXXXXXXXXXXXXXXXXXX

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    I'd have to go 50/50 on this one. Looks like underengineered part failure due to a bit too much fun. How many of these are failing without aggressive offroading, rock crawling and sky king air sessions? Betting it's more of a 6cyl thing vs 4 cyl thing too like the engine mount brackets caving in on the frames when actually doing things like on the commercials they use to sell the things to begin with. Still, depending on price I might be interested in one anyway, even though my 4 cyl isn't doing much if any stuff to have problem.
     
  17. Dec 8, 2011 at 4:15 AM
    #17
    84Hilux

    84Hilux Well-Known Member

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    Nice job! I will check my truck tomorrow. It looks like you use your truck for more than getting groceries!
     
  18. Dec 8, 2011 at 4:28 AM
    #18
    jandrews

    jandrews Carolina Alliance Southwest Region Ambassador

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    From what I understand, they're Dana built. Toyota design and Dana built? In that case, shitty Toyota designs followed by revisions after...etc. etc.
     
  19. Dec 8, 2011 at 7:20 AM
    #19
    Wildhorse1966

    Wildhorse1966 Active Member

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    this woudnt have happened if you had ATRAC
     
  20. Dec 8, 2011 at 7:53 AM
    #20
    Brandon H

    Brandon H Well-Known Member

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    I agree. A-Trac would have kept your old crossmember looking like brand new!!
     
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