Process to replace rusted rear bumper support with pics.

DISCLAIMER: Initially this thread started out as a question, but when I didnt get much, I changed the title and just dove in for myself. This explains the progression of the posts.

Hey all, went to remove my hitch cover and found the support is rusted through. Spent 12 years of its life, before me, in PA. Big chunks of metal fell out and was able to put a finger through it . Apparently this is fairly common. Ordered a new one on eBay for $78. (2018 price) Part #5204304010.

I see its bolted to the bumper in a few spots and wondering if it could slide out above hitch receiver towards the front.

Spent several hours removing seized bolts on trailer hitch yesterday. 19mm. Read as:sawzall

 

So I got into this this am. Quite a rusted mess. Most bolts broke except for the 4 that hold near the hitch receiver brackets. They were quite a bit rusted and took alot of force to get out. And they were too deep for the impact wrench. They'll will be replaced as well.

Fwiw. You must remove the bumper to get to the reinforcement. You can't get the reinforcement out from under the bumper otherwise. The hitch receiver can stay in place.

BTW did call Toyota and they did not want to replace this for me, even though they did service the frame.

 

Post pics coming soon. Cut off a few seized bolts from bumper and reinforcement. Wire wheeled, hammer and chiseled, loctite rust jelly, washed, then repainted. Begin reinstall process.

 

Ended up buying new bumper supports and fasteners all around in addition to the reinforcement.
Diagram below helps considerably. New bolts went in considerably faster that rusted ones came out. Most small ones broke off. Complete reassembly was about 30 mins. Most time was spent waiting on parts to arrive.



Here is an image with part numbers outside of the bumper support. @netmagi (thank you!)






Total cost
$38 new bumper supports Amazon
$78 new bumper reinforcement ebay
$31 new bolts stealership. Yeah that wasnt expected
$147 + time.
Probably looking at $500 at the stealership.

 

Thanks for posting this!

I just took my hitch off today to hit it with a wire wheel and repaint it and come to find out the trailer hitch wouldn’t come off without the bumper support because they were basically rusted together. After I finally got everything out I realized my rear bumper support was in worse shape than the trailer hitch... but thankfully neither of them have any rust perforations and it’s mostly surface rust. I decided to tackle cleaning up and restoring the bumper support today and I’ll have to get to the hitch next weekend. I didn’t take any before pictures of the bumper support but here is my trailer hitch. I might have time tomorrow to start grinding away at the chipping paint but I don’t think I’ll have enough time to paint it. I’ll take some pictures of the refinished bumper support tomorrow, once it is dry and ready to be reinstalled.

 

Damn son! Gotta keep that area sprayed off, in the winter especially.

 

Yeah this area is severely rust prone. Takes the brunt of salt damage. I actually had the same thing happen. Thought the hitch was bad then when I got into it found out the bumper support was worse!

As you can see the rear cross sill is is also pretty bad. (Sits below bed). Found one from at a salvage yard, restored it and replacing it this week. Don't forget naval jelly rust remover if you need it. Lowe's has it. Works great after wire wheel.

 

I just replaced my bumper support last fall. 2012 truck and bumper support was shot. Didn't last 5 years.
From my observation, the design was poor.
Since the bumper support is U shaped with openings in the top side it catches and holds water until it evaporates out on a hot day. There are no drain holes.
I drilled 2 drain holes on the bottom side and poured POR15 in and slooshed it around to cover. Just dont submerge the weld nut threads. Would make for a tough time to install bumper bolts

 

Funny you should say that. An older gentleman I showed this repair to used to work at Studebaker. Within 60 seconds he said the same thing. "Drill 2 holes or it will rust again."

 

Ugh... I just broke two of the bolt heads off trying to reinstall my rear bumper. The hitch and bumper bar restoration turned out pretty good but I knew I should have bought new bolts...

 

Yeah the smaller bumper ones nearly all broke on me. Got some replacements from Lowe's. It was a common thread and pitch.

 

Wish l would have taken pics of mine when l was doing it.l knew mine was bad but not to the point when l took it off and saw it.lt all started with wanting a color matched bumper. l found a slightly dented one off a wrecked taco.Had it fixed and painted white to match my 2010.l ended up taking the bumper assembly off and soaking (bolts) it daily with Blaster for a few days.l got everything apart with no broken bolts and reassembled everything on the new bumper.Every bolt got a dose of Red n' Tacky before reinstalling.
Turned out great except for the inner assembly is still rusty junk.About a week later l found a hitch (same body shop) that was in good shape.lts getting powder coated and should have it back in a week.Glad l greased all those bolts.Shouldn't be too hard to come apart this time!

*thanks for the heads up on the eBay part @Benny123

 

As a Michigan resident, I'll be adding this to the list of To Do's at some point...

 

Looks really good, and I am sure it feels good to know you added more years to it.

Thank for the tread. Another thing that I should look in to this summer.

 

Well, I just ordered the new bumper support. Broke two more bolts off trying to remove the bumper cover so I could extract the two bolts I broke the other night. At this point the original bumper support can rot in a junk yard with four broken bumper bolts in it. I also ordered all new bolts that hold the cover on so as soon as I get the new support and the bolts I can finally reassemble everything and drive my truck again...

And at least the hitch restoration went well and it went back on with no probalems. It looks good and should be ready for another few years of salt abuse. I’m definitely going to drill two holes in the bottom of the new bumper support before it goes on the truck and I’ll be spraying off the underside of the rear often every winter in an attempt to keep the salt from building up. I don’t ever want to have to do this again!

 

Glad to have helped everyone. Tacos up north need a little more tlc to keep them going. I didn't want rust to extend into the frame and painted panels. I ended up replacing my rear cross sill this weekend. Got the part from a salvage yard and refinished it. My original was nearly as rusted.

I was quoted over $1000 for labor alone so I said f it. I'll do it.

Heres the link to replace the cross sill. Truck is now 99% rust free. Last pic is with new sill installed.

 

Looks good man!

And I was lucky in that my rear sill plate didn’t have a spec of rust on it. And neither did the side bumper brackets either. My biggest issue by far was that stupid bumper support beam and all the bolts that screwed into it. The hitch was a bit rusty but after a good grind and some rust inhibiting paint it looks better than ever. I’m just really hoping to have all the new bolts and my new rear bumper support bar by Friday so I can finally put this thing back together and drive it again.

 

Working on this project as well, thanks for the posts and help. I broke only 2 of the m8 bolts luckily.

I noticed the back side of the square hole for the hitch has no cover, seems like water will go directly through the hitch from the back (the side most forward on the truck). Anyone plug this up? Would a plastic cover the same as the cover for the hitch on the rear work?

 

I got an OEM square Toyota plug. I felt like it was an entry point for salt. There are 2 different sizes, measure first. The RAV4 one does not fit.

 

What paint are you using?!