2002 Frame Rust Question Tundra

I have my first frame hole. Most of the frame looks pretty good but this area is pretty rusted with large chunks falling off. I found this hole by poking my finger through it. Should I get this welded? IF I take it to the dealer will they evaluate honestly or just tell me to buy a new truck? How do you know when your frame is unsafe?

 

Well my friend, you've come to the right place! Rust is like ants, if you see one, there are always more... Take it from someone who has spent this year repairing rust on a 2001. It can be fixed, but it takes a lot of work. If the truck has not had the recall steps performed, its possible the dealer will look at it, but the first place they look for perforations will be on the rear cross member, where the spare tire hangs. You'll have to start going over the entire frame with a small hammer, to see what other spots are soft. The 2 most common areas are the boxed sections at the front, where the body mounts are located and the rear section, where the spring shackle mount is attached to the frame.

And welcome to the club...

 

Are you sure that hole was there intentionally? Can you check the other side? If you have the same hole on the other side, then it's not likely a rust hole.

 

Looks like a stamped rectangle that has some rust. Investigate farther. If not too bad begin PB Blaster Penetrant Spray showers all up into the boxed area to soak those lapped metal boxed frames. One or two cans will get you started before winter. Apply a film of grease with a sponge on everything as well. PB and Grease everything frame and axle related.

 

It is a rust hole to be sure. So do I hire a welder to clean it up and reinforce or do I take my chances? Will Toyota condemn my frame if I bring it in?

 

https://www.tundras.com/threads/early-1st-gen-2000-2003-tundra-frame-replacement-faq.54331/

 

If you want to fix, then follow this guy.

 

^This.

That doesn't look like a hole that was created by rust -- it's too uniform. Take a wider shot to show where it is.

 

Up toward the front. Would you get it welded or is it non-critical?

 

That is what I would describe as a semi-critical area.

Mine was identical to what you're showing, plus more along the sides of the frame horn. I ended up purchasing this kit;

https://www.autorust.com/product/front-frame-section-art-213-s-set/

I welded it in place. Again, it's not an easy task. Loads of prep work and fabrication work as well.

You could clean in up, weld a patch over the hole and soak it with PB Blaster and it would probably last a few years. The inside of those boxed frame sections are no doubt full of loose rust and scale.

 

+1 for the Autorust part! I used one of their shops to have it installed. The whole deal cost me $700. Since then I've been scraping and treating (rust converter) every rust spot that's visible. I use East Rust Encapsulator paint to finish the area, and Eastwood Internal Frame Coating for inside the frame.

 

Unfortunately mine is a two door and the kit won't work. Yes it is full of rust and scale but the hole is my only real soft spot. I am trying to get a couple of more years out if it. It has 235,000 but burns no oil. I have a guy who says he an weld up the hole and put some reinforcement on it for 250 bucks. What do you think?

 

That was my plan before I found autorust.

 

Dang I wish somebody made a kit for a two door.

 

Sounds like a good plan. Assuming there will be a fabricated bracket type plate over thats welded on top of the existing hole? Extending a bit off both sides of the hole to gain strength back?

 

I'd check with Autorust and see about that. Although the ad states 4 door only, it worked fine on my Access Cab. If you think about it, the trucks are all the same from the front bumper back to about half way through the doors. From there the cab and frame changes depending on which body style. 1st chance I get I'll measure my frame cap and send you the dimensions. I think it would work fine on your truck.

Depending on how much welding this guy will be doing, and how good it looks afterward, 250.00 sounds decent. Do yourself a favor and check out the photos in my thread. Theres one Towards the start of the thread that shows the undercarriage when I bought it. You can see the angle iron that someone crudely welded on to the rusted frame. You DON'T want that....

 

the rest of the frame looks too clean in this pic for it to be a rust through, IMO
odd shape for a rust hole, too?

should just read the rest of the thread before i post

 

This doesn't appear to be the same hole as the first photo.

 

Great observation Inspector. I’m wondering what other areas may be infected.