It's possible that Toyota will replace the frame under an extended warranty/program. There was a campaign a few years ago to take care of vehicles with rusted out frames. You'll have to take it to a dealer and see what they can tell you. Rust is a big problem on theses vehicles.

 

you can attack rust with a air tool called a needle scaler if you have to get the flakes off

 

So I am about 1.5 hours away from any Toyota dealer, but I am taking it to a friend of mine that would beable to blast and epoxy the frame. I will report back with the cost. Then on my next day off, I will attempt to make the drive out to a dealer to see what they have to say.

 

terrible idea. take it to the dealer first. Your friend will still be there if the dealer says that it does not meet rust performation. If you do any DIY fixes, Toyota may say that you have invalidated the program or some sort of nonsense. Search this forum for a thread that I stated about the lawsuit being settled. It is full of information.

 

So I recently acquired a gently used, 1 owner, 2003 Sequoia SR5 4wd last week, it has 173k miles and runs great. The trailer hitch is so rusty it has more layers than a flaky biscuit. The rear axle and control arms are also flaky, but not as bad. The exhaust is completely rusted through and I will need to replace all of it, Cats included. The frame is rough, I have not checked for perforation, but will probably do so this weekend.

What are my options in dealing with the rusty frame? Any hope of me getting toyota to replace the frame?
[Go and check if your SUV was on a recall list. Many Tundra's and Tacoma's have been recalled because of the frame and undercarriage severely rusting away from salt on the roads and close to the ocean. It all started when they changed the box framing to "C" framing. It was first noticed when a Toyota Tacoma Owner had a service station put his car on a lift for service and the frame broke completely in half. /QUOTE]

So I recently acquired a gently used, 1 owner, 2003e quoia SR5 4wd last week, it has 173k miles and runs great. The trailer hitch is so rusty it has more layers than a flaky biscuit. The rear axle and control arms are also flaky, but not as bad. The exhaust is completely rusted through and I will need to replace all of it, Cats included. The frame is rough, I have not checked for perforation, but will probably do so this weekend.

What are my options in dealing with the rusty frame? Any hope of me getting toyota to replace the frame?
[/h]

 

Go and check if your SUV was on a recall list. Many Tundra's and Tacoma's have been recalled because of the frame and undercarriage severely rusting away from salt on the roads (snow areas) and areas close to the ocean. It all started when they changed the "boxed" framing to "C" framing. It was first noticed when a Toyota Tacoma Owner had a service station put his car on a lift for service and the frame broke completely in half.