Gas tank cross member replace or repair?

Has anyone ever replaced the gas tank sub frame cross member that supports the tank in the rear? Wondering if a shop could do this work if it isn't astronomical. I can source the part for 300 bucks. It's bolt on by 8 bolts but the tank would obviously have to be dropped and whatnot.

I was doing some undercoat on my 04 and noticed the cross member is rusted through on the rear where the tank strap support pin is located. My tank is full and I pushed the tank as hard as I could and it's not even moving at all. The front side where the pin is attached is still intact and sturdy.

The frame looks fine literally everywhere else including the front support cross member. I took a hammer to everything including this cross member. It still seems sturdy other than the places where it's rotted through. I will be ratchet strapping the tank to the frame for extra support and peace of mind for now. I really don't want my tank falling off.

Thoughts? Have someone weld pieces on? New cross member? (if it's even possible to have done without paying so much)

Photos added below:

 

Post some pics so we can see what we're workin with.

 

Ok

 

A shop could definitely do it. I would personally buy a new one. The steps would be pulling the bed, dropping the tank, getting the charcoal canister out of the way and then remove and replace the cross member. After replacing my gas tank and fuel pump, I would say it's not a terribly difficult job. But you have to have the time, space, and energy of course. I'm guessing a shop would probably bill 6-10 hours, just my guess. I would replace your fuel pump and gas tank gaskets while the tank is dropped if you go this route.

 

Photos uploaded. Best I could do. Sorry for the Fluid Film all over. Obviously this truck never got a new frame. But it was probably checked over some years ago and nothing was found. The frame other than this looks pretty good.

 

I might end up getting it replaced after I call around to see what the locals would charge. It'll probably be awhile though so I can work up the cash. I just spent a lot on the other maintenance items on it.

 

If you hammered it and didn't find any soft spots its probably ok, may be able to find a junk yard replacement. If you get one shipped from texas or another desert state it will probably look factory. Did the same thing with a subframe on a rav4.

 

I found a factory new one for 300 bucks but yea. I did hammer everywhere else around there and nothing happened. I went over the hole frame with a hammer. I might strap it up for peace of mind and pony up the money and get the fuel pump done as well like crusty mentioned.

 

You could do the job yourself, bed removal isn't very hard if you have a buddy help you, the rest of it is pretty strait forward.

 

It's toast. Replace it.

 

It seems pretty intimidating but I might give it a go. YouTube is always helpful

 

the bed isn't as heavy as you think it is, the rest is easy.

 

Depending on how rusty everything else is when pulling it all apart.

 

hes says the rest of the truck is pretty clean.

 

My concern for you would be whether you’d have enough wiggle room to flex the new member in without taking everything else apart since the ends fit inside the c-channel. I just replaced my rear frame rails and crossmembers. How’s the rest of the rear end?

 

I have built a few replacements though with steel prices today it is not going to be as cheap as it was.

Then living where you are you should be lucky and not break the fuel pump bracket and other hardware.

good idea to also inspect the fill and vent hose moving them after years can easily crack them.

 

It's not really that bad. It does have 260k miles and driven in a salt state but everything is pretty solid. I'm not gonna say rust free because that's not what it is. The rails are in great shape and the only other bad part is behind the rear leaf brackets. One of the bed hold downs has rusted out. The plastic above the fuel tank seem ok but I am concerned about breaking that stuff too now that it was brought up. What a pain in the ass.

 

Literally the bolts holding that cross member on don't have rust on them. Just odd how it all works.

 

Local shop charged me 275 bucks to replace the cross member. She's looking good. Also had them swap the fuel pump for good measure. Tank was in good shape. Stopped by the shop today to hand them some front dif fluid so they can do that while they have it. Exhaust will be replaced as well because that was original and broke in 2 places when they removed it. Will have the truck Monday. Photos to come if anyone is interested

 

im interested