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Frame rot

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11K views 17 replies 10 participants last post by  ZerosFJ  
#1 ·
The frame on my 2011 to cruiser is rotted. Is there any recall on it ??
 
#2 ·
Take it to a dealership and see what they say. They are replacing Tacoma frames in certain instances that are no more than 15 years old. I don't think they are replacing many FJ frames since we they were build in entirely different factories than Tacomas but it doesn't hurt to try. That's about all you can do.
 
#9 · (Edited)
This Class Action should take the same path as the Tacoma, 4-Runner and Sequoia ... fundamentally the same frame (4-Runner and Sequoia) and manufacturing methods. So it's wait and see for the immediate timeframe.

In the meantime I personally would not do any heroics ... like Por-15 ... etc ... could compromise an ultimate settlement. Fluid Film ... etc ... probably not an issue. Let Toyota tell you specifically (documented) what to do if anything so it's on them.
 
#14 ·
Actually, it is quite different:
The Taco issue was improperly coated frames (the supplier in NA did not follow the approved process) so they rotted out in very short time (well short of 10 years). The FJ and 4-Runner frames were made in Japan and do tend to last well past 10 years before rust through.

The FJ issue is normal corrosion performance of truck frames (shared by all trucks on frames). The majority of FJs are 16 years old, the youngest are 9 years old.


"In the meantime I personally would not do any heroics ... like Por-15 ... etc ... could compromise an ultimate settlement." - that is backwards reasoning. You can choose to do nothing and wait and hope for a good result of the class action lawsuit, but if it turns out the above is true then you'd have missed the opportunity to take care of your truck and get nothing.
 
#12 ·
Salt Kills these frames ... so unless one lives in the Winter "Salt Belt" or specific "Ocean Coastal" regions ... this is not a major concern. I live in Seattle where it's perpetually wet 6-months of the year ... 4-Runner, Sequoia, FJ Cruiser ... all non-garaged ... has never been an issue other than superficial surface rust specifically around weld joints.
 
#17 ·
"where is this documented ?" in the materials related to that Taco class action lawsuit.

The shape of the frame isn't significant, it is the way the members are welded to each other.
A thin sheet metal body of a car (and of our FJ body) would rust away very, very quickly, but the edges of the panels are all covered and protected so that there is a uniform coating over all of it, blocking exposure to water and oxygen. Also, the spot welds are not susceptible to starting rust.

A truck frame is quite different from that, so even though it is many, many times thicker than the thin sheet metal body, the edges of it rusts rather quickly. But, because it is thick, the industry has not cared much about it.

Look underneath any OEM truck, and see how most are covered with red rust after just a few seasons (in the rust belt).

The issues with the truck frame are:
- the stick welds rust quickly, because the factory coating cannot bond to them as well as to the rest of the surface
- the thick steel frame members end with sharp edges, which result in thin/no coating on each edge, so rust can start.

The steel is quite thick, so, historically the red rust has been considered merely cosmetic. For most OEMs, a 10 year life is doing pretty good, so perforation was a pretty low risk for them. But, for Toyota, with these days typically >20 year life span, that rust becomes a bigger issue over time, leading us to where we are now.

The taco lawsuit was because the coating was incorrectly applied, so they had areas of bare steel, which rusted through much faster than 10 years.
N
 
#18 ·
There are multiple threads on frame rust. Please use the search. This is a common issue on all vehicles worldwide which are body on frame construction and where roads are salted.

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