2004 4Runner Sport 4WD V8 Frame Rust in One Area - What to do?

I bought this new back in 2004 thinking I'd drive it to 250,000 miles. It's at 180,000 now, never used off-road and has lived in the south (no snow, salt, etc.). Six months ago the passenger side lower control arm broke (rusted), so between replacing both sides upper and lower control arms, all 4 struts and springs, front and rear pads and rotors, and tires, I figured I was good to go. Looked over the frame for any significant rust and it looks great - except for one area. I'm not liking what I see. What's so frustrating is that everything is good to go except this one area.

Here is the problem area - front passenger side near the cross member that ties to the transmission:

Rest of the frame looks great (to me at least):
Driver's Side:

Passenger Side:

Overall Vehicle Condition:

 

I'm guessing you live near the ocean. That's your source of rust.

Regardless, it looks good overall and I would just get that section welded and repaired.

 

Hard to tell exactly from the photos but it sounds/looks like the reason it's rusting in that area is because of the HVAC condensation drain that drips down on the frame at the rear of the passenger's side wheel well, the drain comes out of the firewall directly above the frame and constantly drips down on top of the frame.

The rust will have to be fixed, to solve the drain dripping on the frame issue, you can add a piece of rubber hose to the drain hose coming out of the firewall and route the drain down and away from the frame so it drips on the ground.

 

This is what I've been thinking as well - only way the rust could be so concentrated. At this point I'm ready to move on to another vehicle, but what's the best option to get as much back as I can after dropping something like $4000 in recent repairs (pads, rotors, upper and lower control arms, tires, etc.)? I'd never list this for sale without disclosing this issue, and if I fix it then I'm getting deeper into the hole and think the repair will be obvious and still need disclosure. I can't find many V8's for sale online and the engine and transmission are both running great.

 

My advice is call this guy and get some advice. He is worth a drive up north in the spring also. Look up his videos very impressive knowledge and seems very honest. Seriously worth an email and phone call for sure.

 

Thanks! Will do.

 

This doesn't help you but it's astounding that Toyota would miss something so obvious in not putting a hose on the condensation drain, and that's true of a vehicle that isn't rotting out from under a considerable number of its owners. Here's a I did if you want to run the tube, either now or if you get that fixed up.

 

@DH777 - I checked with a friend who has new Saf-T-Caps leftover from her frame repair, but hers are for the rear part of the frame.