WHY do Tundras have frame rust problems?

We have talked endlessly about what to do about this problem....but I don't think I've ever seen anyone say WHY this problem exists in the first place and why supposedly its worse on Tundras than other vehicles? What made it so bad that there was a recall?

 

It persists to some degree even these days. They recently added a process last year to spray some underbody areas with a wax type compound to address issues in problem areas as they are leaving the plant.

 

So what are they doing wrong that other automakers aren't?

 

Poor ingredients/milling techniques in the steel. Also, I believe there is a dielectric connection issue with the crossmembers being a slightly different metal content. Mix in some salt/brine to accelerate and the results are what we see.

It also is important to run Phosphated Coolant in your engine as that offsets the Iron to Aluminum chemical reaction there.

 

Probably the reason you don't notice in the big 3 is they're worn or rusted out after a shorter period of time

But seriously, I've always noted how Jap steel parts aren't quite the same over the years. The finish looks more anodized than other cars on the heavier steel components. Even the fasteners

 

It’s not just tundras, it’s most toyota frames in that 90-00 era that have issues

 

There may be some truth to this.

My friend had a Ford that he used for his electrician business. It was 8 years old and in very good condition both mechanically and body-wise. He took it in for the annual inspection, and it failed because the frame was completely rusted through in multiple location -- not safe to drive off the lot.
He said, "This is only 8 years old! What are you going to do about it." They said, "We'll sell you a new truck!" He said, "I don't think so."

He now drives one of those Nissan cargo van things. Ugly as sin, but a well-build vehicle that suits his needs perfectly.

 

The rust issues associated with Tacoma's, Tundra's, and Sequoia's, was due to Dana Corp making the frames improperly. Toyota won a multi-million dollar lawsuit against Dana Corp as a result. With the hassle and bad press, I'm sure Toyota has since taken steps to ensure that rust-preventive measures are taken as speced.

 

That's Toyota's company line.

FYI: Comparable year 4Runners have effectively the same frame as the Tacoma (albeit with different rear spring perches) and they have the same frame rust problem. The only difference is that the 4Runner frames are made in Japan by Toyota so they can't pass the buck to Dana. The Toyota company line on 4Runners is that there is no problem... because the remedy would be on their dime.

 

While they do have rust problems it is no where near as prevelant as the tacos and 4runners


But everyone seems to ignore the Colorado and wrangler rust issues.

 

Yeah it was an issue on Dana's end, but they still use Dana for frames and to be honest they all still seem to rust quite a bit. I had a 99 taco and 08 taco that both frames rusted out on, so in that 10 year span the issue wasn't fixed and they knew about it well before 08. The frames on tacos continued to rust out after 08. Same with tundras, my 15 would be in rough shape if I didn't take measures on my end to prevent rust. Dana still makes frames that rust out and toyota still puts them under their trucks, I dont get it but I'm sure its comes down to saving a few pennies

 

I had a 2012 Tacoma with no issues at all but who knows now I guess.

 

10 and up I believe are made by metulsa. At least the replacement frames are

 

I did not know that. Thank you for providing accurate info, lol. I thought they still used Dana, which I couldn't understand why they would stuck with a company that screwed them over

 

I’m not sure who made the T100 frame, but I just sold my ‘96 (that my Tundra replaced), never did anything to protect it from rust and it looked great, there was just some light surface rust here and there. Not saying doing nothing for your frame is a good idea, but I’d never experienced rust before the Tundra.
I had some cheap helper springs I put on it about 10 years ago, and they were the rustiest thing under there, I suspect a cheap grade of metal, makes me think the grade of steel used in these rusty frames is largely to blame.
It’s amazing Toyota hasn’t done more to improve the situation over this many years...

 

Where my Tundra has lived it's whole life, west TN, we hardly ever have much snow anymore, which means no salt on roads for the most part. Would that not be why some veh like mine have hardly any bad rust issues !

 

Yes. I'm in east TN and my truck has very little frame rust. It spent most of its life in Ashevillle, NC where they get more snow but apparently not enough to do any damage.

 

Hoping for snow in a week 1/2 when we get to Gatlinburg, at least up top

 

My dad drives a 1998 Dodge Ram and has never washed it since the day he brought it home. The body is rusted bad rockers and bottom of the doors are gone along with wheel wells. I thought for sure the frame would be toast but it's actually solid. There is some areas where it is pitted but it's nothing that is going to cause the frame to fail. I really hate that truck and i can not stand Chrysler quality but they did the frames right on that Ram, the sheet metal not so much...

And yes it is driven in the rust belt every year and the salt is never washed off of the thing. I am actually joining the forum because he is looking at replacing this Ram with a 2001 Tundra that has had a frame replacement and just trying to learn more about these trucks since i have to work on it. A friend of mine has a Tundra with close to 400k the body is in decent shape but the frame is pretty bad. I plan on using wool wax to undercoat it and make it last longer.

 

Welcome then and you certainly came to the right place! Poke around a bit and holler if you have any questions!