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I just took my 07 FJ in for it's inspection. I was notified that it will not pass because there is a rusted hole in the frame. The staff at Toyota had me contact Toyota Corporation to set up a claim. I did this and was notified that there is nothing that they can do because there haven't been other FJ's with this problem. This is a similar problem that the Toyota Tacoma's have been having and their frames are being replaced free. My wife and I always use Toyota and enjoy working with them but this is just wrong. What can I do?
 

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That is insane. Where are you located? I don't think it will be long before more cases pop up. I'm not even that far north and all the FJs I looked at recently during my quest to buy one were plagued with huge rust issues.
 

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Double ck your manual. As far as I know it is 10 years unlimited miles on rust through. If they say no, show them the manual. If they still say no, contact a lawyer and the NHTSA. This is the main reason I sold my Tacoma.
 

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There have been other cases of this. Do a search for frame rust on this forum. I know at least one or two people have had to have their frames replaced. I am not sure Toyota paid for the new frames, but none-the-less the frames needed replacement due to rust or cracks.
 

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Very interested in what happens with this. I have some rust spots underneath but it all appears to be surface rust only but I do worry about the inside of the frames - the rust you cannot see. I'm not sure about my vehicle but to my knowledge it's only surface rust on mine.

I'm interested knowing if whether the manual does specify if rust is covered for 10 years/Unlimited mileage. If so I'm interested in being a test dummy here by going to Toyota with it. I have 4 Toyota Dealerships in my area and would love nothing more than to push their buttons lol.
 

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the frame of my fj 2007 (second hand, 70'000 mls) is tomato red. seems like it never had any protection...
unfortunately toyota did not import the fj in switzerland. it is a direct import from usa.
i do not see any chance to get warranty support from toyota. the last offer from a german specialist to get rid of the rust: 2'500$!
is there someone having the same problem in switzerland or germany?
my first intention was, to use the "ice-peeling" method. but i do not know if it would be to risky
 

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I just took my 07 FJ in for it's inspection. I was notified that it will not pass because there is a rusted hole in the frame. The staff at Toyota had me contact Toyota Corporation to set up a claim. I did this and was notified that there is nothing that they can do because there haven't been other FJ's with this problem. This is a similar problem that the Toyota Tacoma's have been having and their frames are being replaced free. My wife and I always use Toyota and enjoy working with them but this is just wrong. What can I do?
I'm not happy with the lack of rust protection and/or the alloy used in the frame and suspension bits- I have a ton of flake and metal delamination that concerns me about keeping this thing 'forever'. I live in western WA and do go skiing in the winter so it sees a modest amount of salts. But I do rinse afterward and still there's a bunch. I work on vehicles for a career and haven't seen similar rot on rigs that weren't 20+ years old from our geographic locale. Toyota did a poor job on the frame. Yours isn't the only one. I've heard of people getting frames replaced in earlier years on this forum. Don't let Toyota dealer bulls*hit you.
 

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Very interested in what happens with this. I have some rust spots underneath but it all appears to be surface rust only but I do worry about the inside of the frames - the rust you cannot see. I'm not sure about my vehicle but to my knowledge it's only surface rust on mine.

I'm interested knowing if whether the manual does specify if rust is covered for 10 years/Unlimited mileage. If so I'm interested in being a test dummy here by going to Toyota with it. I have 4 Toyota Dealerships in my area and would love nothing more than to push their buttons lol.
I'm pretty sure the last job any dealer tech would want to do is a frame replacement-possibly this alone spurs the denial. I say boo hoo to them.
 

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I have a 2013 FJ. I also swear by Fluid Film as the best rust buster / preventer on the market
I have 30,000 miles, live in San Diego and have no rust. It's gotta be a salt on the road connection.
I do spray ALL my exposed electrical and sensor connections with fluid film. Fluid film will not dry out or conduct electricity. Fyi don't waste time or money on WD 40. It's kids stuff.
 

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x2 Fluid Film (or Waxoyl, or Boeshield)

If there is much red rust already visible then at first flood the frame insides Ospho to convert as much of it as possible to iron phosphate, and then flood the inside with FF, and reapply it every year from then on.

Sadly, this won't help anyone who's already rusted out their frame, but to the rest who start caring for theirs in time they should be better off if they do this.

The Tacoma frame issue was in '08, so especially the first year of FJ manufacture people ought to take special care. IIRC, the Tacoma frame issue was a local, NA supplier problem, so our FJs (built in JPN) ought to not be directly like what had happened with that other project.
 

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1) I don't understand the logic behind the statement that since it never happened to anybody else (which is total BS) Toyota won't cover it. It happened to YOU which means it happened.

2) If it happened during normal driving and you have taken you car in for regular service, I don't see how Toyota NA has a leg to stand on. Why wasn't it caught before it became an issue that made your vehicle legally undriveable?

3) I was checking out the worst vehicles in terms of rust problems just yesterday and no Toyota vehicle was even among the top ten. Jeep, BTW was either number 1 or 2 in terms of serious rust issues. I am not a Jeep hater but that is what I read. I hesitate to mention it since I can't find a citation, but if you are more ambitious than me at 6:30 AM (coming at it from an all-nighter) you might want to check it out.

4) I have heard more than a few people complain about underbody rust. Given that we live in a (supposedly) free market economy one would think that somebody could make a fortune if they came up with a reliable rust prevention formula for the undercarriage. As an economist I don't understand the missed entrepreneurial opportunity to make $xxx,xxx,xxx given that Toyota now sells more cars and trucks than any other automobile manufacturer.

5) I talked to the owner of one of the most reputable after market 4x4 shops in DFW literally just today (Tandem Automotive) about this very issue and he said there wasn't much of a market for it here, even though he stated that he has several formulations in the R&D (alpha testing) stage for complete undercarriage rust protection. He stated that he would be happy to do a serious undercarriage wash, rub away any surface rust and treat such areas with the best rust prevention formula he knew of, but implied there just wasn't much of a market for it here.

These guys are FJ fanatics and probably have more of them up on their lifts per week than any dealership in DFW. If there was big money to be made in undercarriage rust removal, this guy is certainly smart enough and motivated enough to stay up nights trying to figure out how to take advantage of it

Just several somewhat conflicting observations.

I remember back in the day when the most common dealer upsell was an underbody coat (anybody remember the movie "Fargo?"). Now not so much.

Unusual rust problems under the body should be treated just like any other warranty claim: as an anomaly that a company wants to take care of in order to maintain their reputation.

Good luck friend.

You deserve to be compensated and the rest of us should have an opportunity to purchase something that absolutely and completely protects our undercarriages from rust, especially our brothers and sisters in the snow belt.
 

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When I bought my FJ last year, I used it on the undercarriage and wheel wells to get me through winter. Considering I never cleaned it first, it held up through winter and delayed the spread of the rust that was on it.


Sent from a NiPhone, using auto-correct to eff things up with Tapatalk
 

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When I bought my FJ last year, I used it on the undercarriage and wheel wells to get me through winter. Considering I never cleaned it first, it held up through winter and delayed the spread of the rust that was on it.


Sent from a NiPhone, using auto-correct to eff things up with Tapatalk
Thanks.... I was actually planning of applying it and good to know that it really helped delaying the spread of rust.
 
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