1. Welcome to 4Runners.com!

    You are currently viewing as a guest! To get full-access, you need to register for a FREE account.

    As a registered member, you’ll be able to:
    • Participate in all 4Runner discussion topics
    • Transfer over your build thread from a different forum to this one
    • Communicate privately with other 4Runner owners from around the world
    • Post your own photos in our Members Gallery
    • Access all special features of the site

2005 Rusted Out Frame

Discussion in '4th Gen 4Runners (2003-2009)' started by Bostonaustin, Feb 19, 2016.

  1. Mar 12, 2019 at 5:25 PM
    #31
    NOLA Dave

    NOLA Dave New Member

    Joined:
    Feb 27, 2019
    Member:
    #8989
    Messages:
    10
    Gender:
    Male
    First Name:
    Dave
    Vehicle:
    2005 4Runner sport edition
    I thought about having somebody weld a knew piece of steel to replace the beam under the radiator, but since it's in litigation then maybe I shouldn't touch it, also thought about drilling some holes where needed for drainage, afraid if I touch anything they might deny a claim? Well I hope you guys get favor that have the older models because that all sounds the same to me.
     
    HoBoDanny likes this.
  2. Mar 12, 2019 at 5:34 PM
    #32
    jdevtac

    jdevtac New Member

    Joined:
    Oct 17, 2017
    Member:
    #4904
    Messages:
    25
    Gender:
    Male
    Vehicle:
    02 4Runner SR5 2WD
    I know at least for me I’ve already had a safetcap welded in at my rear trailing arm on passenger side so that ship has sailed lol.

    If you are referring to that auxiliary crossmember that the skid bolts to I’d just leave it be. It’s not really structural in any way besides being a mounting point. I think we will probably know within the next couple months if this lawsuit is going anywhere or not. It’s either going to get shot down relatively quick or press on.

    On another note have you checked your cooler lines that bolt to that crossmember? If the crossmember is falling apart those might also need replacing if they are super corroded.
     
    HoBoDanny likes this.
  3. Mar 12, 2019 at 6:36 PM
    #33
    NOLA Dave

    NOLA Dave New Member

    Joined:
    Feb 27, 2019
    Member:
    #8989
    Messages:
    10
    Gender:
    Male
    First Name:
    Dave
    Vehicle:
    2005 4Runner sport edition
    Can't tell for certain on the cooler lines cuz there is still a thin strip of rusty metal hanging on just below them, I was concerned about it though, that was the reason I thought about having a new bar welded to protect those lines if I hit something in the road, also because it's so rotted out there ain't much holding that skid on in the front. Yeah it's not too good with those cooler lines right up against that rusty steel. Thanks for the info!
     
  4. Mar 12, 2019 at 6:53 PM
    #34
    Riding Dirty

    Riding Dirty Sinner; saved by grace

    Joined:
    Jul 19, 2017
    Member:
    #4416
    Messages:
    238
    Vehicle:
    2017 T4R Pro 040
    Is plasti-dip a mod?!
    Actually, the 4runner and Tacoma do not share the same frame. Tacoma is a North America designed and built truck, 4runner is a Japan designed and built truck. Early pre-Tacoma pickups/hilux and 4runner did share the exact same chassis, but they are totally separate vehicles now. My 4runner is 21 inches shorter than the 3rd gen Tacoma I had, and a fully boxed frame, Tacoma is open c-channel in the rear. The fully boxed frame is more susceptible to rotting from the inside out (aka, 1st gen Tacoma?!), so if one lives in a moderately to heavy salted area, sea air or northern climates, this fully boxed frame can rot away.
    yes, it's a pain to crawl under my rig and Fluid film it, but my 4runner has zero rust anywhere. I plan on keeping it for at least 30 years, so it is worth it to me. But on the upside, crawling up underneath it allows my to also keep an eye on any potential problems otherwise not related to rust.
     
    HoBoDanny likes this.
  5. Mar 12, 2019 at 9:59 PM
    #35
    NOLA Dave

    NOLA Dave New Member

    Joined:
    Feb 27, 2019
    Member:
    #8989
    Messages:
    10
    Gender:
    Male
    First Name:
    Dave
    Vehicle:
    2005 4Runner sport edition
    Thanks for the information, many people had told me that and steered me wrong on them having the same frames, ha, most of my frame seems okay but if I move up north by family in Ohio I would definitely have a problem and would have to do something like that fluid film I would imagine. Sounds like they made a piss poor design.
     
  6. Mar 13, 2019 at 3:03 AM
    #36
    jdevtac

    jdevtac New Member

    Joined:
    Oct 17, 2017
    Member:
    #4904
    Messages:
    25
    Gender:
    Male
    Vehicle:
    02 4Runner SR5 2WD
    This is another reason why the lawsuit that was started may fall flat pretty quick. They claim 4Runner frames were also made by DANA, which I’ve never known to be true. Doesn’t mean the 4Runner frames don’t have their own issues of course, but still. Targeting 05-11 t4r and then putting up documents that may or may not be with factual info doesn’t seem like a good case for them.
     
  7. Mar 13, 2019 at 5:07 AM
    #37
    Benny123

    Benny123 Long term owner

    Joined:
    Mar 4, 2019
    Member:
    #9045
    Messages:
    23
    Gender:
    Male
    Charlotte, NC
    Vehicle:
    2007 V6 SR5 Galactic Gray
    Stock
    Moved from Ohio to South Charlotte 5 years ago and it was the best thing to happen to my frame. I was shocked when I moved here to see old Ford Rangers from the 90s and Honda Civics from the 80s still on the road routinely. They were gone from OH decades ago, but nothing kills them here....

    Never got really under it until last summer and I gasped at the rust. Fortunately it was mostly surface rust. Took a few weeks a few hours a day to get it all. Scrape, hammer, wire wheel, POR15. But its solid now from the rear wheel area to the front skid plate. Oh yeah drop your wheel, you may find your cable is rusted and the worst damage above the tire. I had to replace mine.

    Salt destroys these frames. You have to be diligent. Even when in Ohio I sprayed off the salt at a car wash every week salt was on the road. I was fortunate since it never ate through the frame. Salt destroys metal, no doubt about it, its chemistry. But I should have POR15d it years ago. If you live in salty areas, do it now, you can get a quart on Amazon. And get a drop sheet of plastic & gloves that go to your elbows. Its nasty stuff.

    The further north you go the worse your frame will be hit. OP was from Boston, and notably never posted back.
     
    Last edited: Mar 13, 2019
    HoBoDanny likes this.
  8. Mar 13, 2019 at 9:03 AM
    #38
    jdevtac

    jdevtac New Member

    Joined:
    Oct 17, 2017
    Member:
    #4904
    Messages:
    25
    Gender:
    Male
    Vehicle:
    02 4Runner SR5 2WD
    I have a new spare tire mount inbound to me. The original was rusted to hell and the wire was kinked. I was glad it at least was able to be lowered so I could remove it. Ended up having to drill a couple holes in the rear cargo floor to get the bolts out because of how badly corroded and seized they were and how tight it was.

    I saw the new models are chains instead of steel cables.
     
  9. Mar 13, 2019 at 11:54 AM
    #39
    Benny123

    Benny123 Long term owner

    Joined:
    Mar 4, 2019
    Member:
    #9045
    Messages:
    23
    Gender:
    Male
    Charlotte, NC
    Vehicle:
    2007 V6 SR5 Galactic Gray
    Stock
    Yeah I thought about buying it but I just recabled it. I made this post last year with instructions. Turns out nobody tried that before. Still holds like a champ.
     
  10. Mar 13, 2019 at 12:08 PM
    #40
    jdevtac

    jdevtac New Member

    Joined:
    Oct 17, 2017
    Member:
    #4904
    Messages:
    25
    Gender:
    Male
    Vehicle:
    02 4Runner SR5 2WD
    Mine was rusted to hell at the piece that sandwiches the spare up to the mount so there was no going back otherwise I would’ve contemplated rehabbing it. The price on the new ones is a bit high, like $145+ but someone on eBay was selling some brand new ones for $75 and free shipping and I couldn’t pass it up. I like the chain model too, it’s what 2nd gen Tacos have too
     
  11. Mar 13, 2019 at 3:11 PM
    #41
    jdevtac

    jdevtac New Member

    Joined:
    Oct 17, 2017
    Member:
    #4904
    Messages:
    25
    Gender:
    Male
    Vehicle:
    02 4Runner SR5 2WD
    This is what I treated over this past weekend (pics after a coat of POR15)

    9CF58085-22DE-4D76-9C8C-CAD012EC5746.jpg

    487E1FAE-EE4A-46B0-8319-4E1D21C768B7.jpg

    The ass end of the frame was pretty pitiful. Busted all the dingleberry pieces of metal and wire wheeled for a good couple hours to get the flakey crap as much as possible. The frame endcaps are essentially gone. Then degreased with simple green and used some of the POR metal prep for shits and giggles. I’ve not been to impressed with the stuff to be honest. It’s worked well for some minor jobs but it’s otherwise pretty weak phosphate converter.

    Hit it with 2 coats of POR15 once it was bone dry and then topcoated with duplicolor engine enamel while the final coat was still tacky. This process worked with me on some OEM Toyota steelies I rehabbed so I hope it does the same for the 4Runner. I’m not a huge proponent of POR15 but this will do.

    Today I followed up on some spots I missed in the rear frame as well most of the inside of the rear crossmember with Eastwood Internal frame coat (green for contrast).

    I’ll give it about 5-7 days before I do a final layer with CorrosionX HD and then leave it alone for 6 months, give it a follow up visual inspection and then let it be.
     
    Benny123 and HoBoDanny like this.
  12. Mar 14, 2019 at 6:04 PM
    #42
    NOLA Dave

    NOLA Dave New Member

    Joined:
    Feb 27, 2019
    Member:
    #8989
    Messages:
    10
    Gender:
    Male
    First Name:
    Dave
    Vehicle:
    2005 4Runner sport edition
    If some people are saying the frames are rusting from the inside out how you going to take care of the inside of the frame if it's boxed in?
     
  13. Mar 14, 2019 at 6:07 PM
    #43
    HoBoDanny

    HoBoDanny Dude...

    Joined:
    Feb 5, 2019
    Member:
    #8697
    Messages:
    712
    Gender:
    Male
    First Name:
    Daniel
    Kentucky
    Vehicle:
    2004 SR5 V6 4WD 4Runner
    RCI Skid Plate CBI Ditch Light Brackets Hankook DynaPro ATM RF10 265 70R17 113T Tires TPMS Bypass Mod Hydrocarbon Filter Removed Merca decal 2” leveling kit front only Black headlights
    There are openings in the frame that allow you to spray the rust proofer of your preference inside. :thumbsup:
     
  14. Mar 14, 2019 at 6:09 PM
    #44
    jdevtac

    jdevtac New Member

    Joined:
    Oct 17, 2017
    Member:
    #4904
    Messages:
    25
    Gender:
    Male
    Vehicle:
    02 4Runner SR5 2WD
    I’ve already hit the entire inside of the frame from front to back with Eastwood internal frame spray after I gave it a good rinsing and removed as many flakey chips as possible with one of those flexible magnet sticks.

    I followed that up with Corrosion X as a final coat and to get to anything I may have missed.

    I used a cheapo endoscope cam to see if I got good coverage.
     
  15. Mar 14, 2019 at 6:10 PM
    #45
    NOLA Dave

    NOLA Dave New Member

    Joined:
    Feb 27, 2019
    Member:
    #8989
    Messages:
    10
    Gender:
    Male
    First Name:
    Dave
    Vehicle:
    2005 4Runner sport edition
    But if you cannot remove the rust first I would think it would still eat through like cancer.
     
  16. Mar 14, 2019 at 6:13 PM
    #46
    NOLA Dave

    NOLA Dave New Member

    Joined:
    Feb 27, 2019
    Member:
    #8989
    Messages:
    10
    Gender:
    Male
    First Name:
    Dave
    Vehicle:
    2005 4Runner sport edition
    Okay I just seen the other post about how to remove the rust, sure sounds like a lot of work, lol
     
  17. Mar 14, 2019 at 6:15 PM
    #47
    jdevtac

    jdevtac New Member

    Joined:
    Oct 17, 2017
    Member:
    #4904
    Messages:
    25
    Gender:
    Male
    Vehicle:
    02 4Runner SR5 2WD
    It is a lot of work and many would argue a waste of time but o-well. That’s what I get for jumping into a purchase.
     

Products Discussed in

To Top