Rust on My 3rd Gen Tacoma: Coming Through Paint

I have a 2019 Toyota Tacoma TRD Off Road 4x4 Crew Cab Long Bed in White.

Around August 2022, I started to notice rust coming from the factory bedside rivets and above the windshield. I took it to Rivera Toyota for them to inspect in September 2022, they documented the issues and advised me to contact Toyota Corporate. After speaking with Toyota Corporate they said they could not do anything about the issue, since my truck was out of the three-year, 30,000-mile warranty.

In September of 2023, I noticed paint in the engine bay flaking and peeling down to the metal. The rust above the windshield had spread aggressively, and the rust from the factory bedside rivets had become more apparent. Additionally, I noticed rust forming and spreading on the metal from both the left and right rear fenders within the area of the factory bed. Troubling, as I have had a Truck Cap on the vehicle since purchasing the Truck. Although not weather-tight, I rarely get water in the bed area of the truck.
I live in Westchester County, New York, which is inland and although we have snow/salted roads and I spend some time down at the beach, I wash the vehicle often, if not weekly - every other week, and take great care of the Truck.
I brought the vehicle back to my Toyota dealership to inspect the vehicle. The Service Director and Assistant Service Manager noted the abnormality of the rust issues, along with the tech, and thoroughly documented the damages. They suggested I advocate for the repairs and reach out to Toyota Brand Engagement for a solution since my truck was out of the three-year, 30,000-mile warranty. The service director and assistant service manager advised that although this is out of warranty, they are concerned with the paint rusting in the bed areas as there is no damage, no rubbing, and no reason why there should be rust forming. They hinted that it could be a defective paint job.

I got in touch with Toyota Brand Engagement, who approved repairs for the paint peeling on the fender from the recent Customer Support Program 23TE08. However, Toyota Brand Engagement said they reviewed the damage and notes provided by the Toyota dealership with both the Toyota Executive office and Toyota Product Specialists.
Without physically inspecting the vehicle, Toyota Brand Engagement attributed the rust to potential water pooling, an explanation seemingly contradictory to the physical orientation of the rust locations and protective factory plastic strip and factory plastic under the truck cap. It contradicts the physics that the rust would form.
I asked for them to provide the documentation on how they came to this conclusion, yet they will not provide the documents.

Has anyone else experienced similar rust issues with their 3rd (Third) generation Tacoma? Specifically, has anyone encountered rust in areas such as bedside rivets or the metal lip of the quarter panel, even with protective measures like a truck cap in place? Has anyone had success with Toyota repairing this issue outside of warranty?

My expectations are low, as it's out of warranty, but I am hoping to hear of anyone with similar experiences in rust-forming on the paint of their 2019 Tacoma or similar years, and in areas where it would not typically form.

 

Honestly you’re in a losing battle. My advice (if financially viable) is have corporate fix the peeling paint and trade the truck. These trucks are a pain in the ass if you live in the snow belt. I really don’t know why I bought a fourth Toyota when my previous three rusted so badly. I guess I’m an optimist.
That “water pooling” excuse has to be the most absurd thing I’ve ever heard when the rust is on a vertical surface.

 

https://www.tacomaworld.com/threads...ailure-thread-with-toyota-corp-update.689940/

I am assuming you have paint code 040

Here is something for you to dig thru re: white paint failure
This is a known issue for sure
Lots of info and some resources

I do not have a white Tacoma but I have friend who just got a new TRD Pro 4R with 040 paint so I told him to be on the lookout.
He keeps his in the garage and we live in the south so [fingers crossed]

GOOD LUCK!!

 

This looks like it may be related to the Super White paint defects. Lots of consolidated threads here in TW regarding issues with the white paint. It’s part of the reason for me not getting a white one this time around. Push the dealer!

 

Too little too late, but read my signature

 

I have a 2020 cement OR. I also have a rust spot above the windshield. I called my local dealership and they told me there is nothing they can do cause the paint is not covered under warranty. On the Toyota website it states:

Rust-Through Coverage
60 months/unlimited miles (corrosion perforation of sheet metal). *
The stealership told me they cannot cover the rust due to natural corrosion, I’m guessing if a rock hits it? I’ll be calling the corporate office

 

https://www.ziebart.com/find-my-ziebart


Put zipcode in and find nearest one. Go and see what they have to say. They do both preventive and rust removal + preventive. Obviously it will cost extra since rust is already in there. Based on how well is rest of your truck doing, if there is no rust on frame lets say, and all is good maintenance wise, might be worth it.

You see those holes that are plugged with plastic cover? woolax/fluid coating fills that, they use oil spray and fill those holes up inside, so it won't rust inside like yours did. It happens to lots of trucks, especially up here in rust belt. Just go to them and see what they tell you.

Toyota is not great handing rust issues, they left both 4runner and Seq to rot, and of course they turned you away too. Salt is not always needed for rust, moisture can do that too, water and that's it over the years.

My brand new literally 15 mile Tacoma I got on from Toyota dealership, had surface RUST already on transmission. Truck was literally PARKED 1month in there and still got rust lol. I knew i had to look under the car and I did, learned hard lesson from my 03 4runner when even break lines rusted out.


And please, DO look under the truck, lets hope rust is only in paint and frame is fine.

WOOL WAX/FLUID FILM is the only way to protect the truck from rust fully.

 

Tell the friends with the t4r to watch around the ‘4Runner’ logo thing on the back hatch, already had our ‘22 paint fixed… it was rusting around the corners.

Op: isn’t the rust and perforation warranty longer than 3/30??

 

White paint failure is not a new issue. I've had it on a 1994 Dodge and continue to see it on many vehicle brands today...daily.
Good luck OP.

 

I’m gonna check the undercarriage here soon. I know my shocks, and other components are rusted bad. I live in Florida with and work near the beach. If I knew about getting the undercarriage coating when I first bought my taco, I would of done it first thing

 

Ok, would be good if you can post pics.

 

here is the pic of the rust that I took this am. There is no way it was from a rock being that close to the windshield and the rust is protruding away from the sheet metal

 

The rust is inside, to the left and right too probably. There is no rock hit yes, it just blew up from inside, either rotted out or moisture bubbled up paint, I am betting it was moisture that was trapped inside.

I would be worried more about frame rather than paint to be honest. Is frame rust bad?

 

I hate to say it, but touch up the paint and trade them as quick as you can. Short-term, you will lose some cash/equity on the trade, but when you factor in the frustration and continued paint deterioration/rust you're going to see, it's an easy choice. This is the exact reason I traded my Super White 2019 for my Black 2022; no way I was going to deal with this when mine started showing signs of paint issues last year. Good luck to you guys, this sucks.

 

No such thing as "rust repair." It's either cut it out and patch it, or replace the part. Any attempted repair will be temporary, and the rust will come back.

Any properly cleaned/maintained vehicle should not have rust coming through the paint at 3-4 years old, even in the rust belt. The rust in the 3rd pic in particular is awful and inexcusable.

 

The frame isn’t too bad. It’s more surface than any. I have an appointment at a Toyota body shop next week and I’m expecting the run around but I won’t spot fighting this until it’s fixed. I’ll take a pic of the undercarriage here in a little bit

 

There is such a thing as rust repair, Ziebart does it , many auto shops do it. Tacoma frame is not boxed, meaning they can clean it both ways. Like 4runner has boxed frame, Seq has boxed frame. Thats when they need to cut pieces out, because rust spreads inside the box, and they can't clean that out, but Taco has open frame. 4rd gen will have boxed frame like Tundra.



He is about to show us his frame yet. If frame is fine the paint might not be big issue, obviously it will cost some, BUT might cost less than a new truck. Its worth checking all options before going out there and getting new truck in todays market.

 

Any "repair" is temporary unless it involves replacing the part, or at least replacing the corroded area. Ziebart and other such shops do not do rust repair. They aren't body shops. What they call "rust repair" is not.

 

Well I can’t get under my truck this second but it’s really not bad at all minus the shocks. Looks like surface rust but that don’t mean anything. As soon as I can get a pic I will get one

 

That's definitely not right. Dont let Toyota make you think you're crazy. I'd be wondering if those panels had rust on them before they were primed at the factory.