Automotive

07 Camry severe corrosion - lessons learnt

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  • Jun 5th, 2020 8:58 am
[OP]
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Jan 8, 2009
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Ontario

07 Camry severe corrosion - lessons learnt

Have been giving my 07 Camry Hybrid a bit of a makeover - touching up rust under doors, repairing some perforation bubbling on the front fender, replacing rotten muffler etc.

While working on the car I discovered a hole in the driver's footwell. It became apparent that most of the floor comprised only non-metallic coatings and some sort of rigid sound deadening material originally applied to the thin sheet floor. It could be broken out with a fist. (Photograph below).

It appears that wherever the material was bonded to the steel that plate was at least partially corroded, including up the tunnel. Beyond the material the paint was fine. In the horizontal areas the steel sheet was gone.

I was shocked at the extent of damage on an 07 vehicle and the way it had been hiding behind layers of sound deadening materials, fitted carpet, and underseal below.

I think the following factors played a part in causing the situation:

- Water from winter use caused wet carpets and foam (this vehicle has never had contoured / deep profile mats (which we now use on other vehicles and highly recommend). Not that unusual to get wet mats in the winter.

- A rigid sound material was stuck to the steel floor before factory painting (as paint was on top). Rust crept between this material and the steel which then had little protection. Directly on top of this was a sheet of water absorbent foam with fitted carpet over that.

- factory rubber backed carpets retained moisture in fitted carpet below. These were always zip tied in due to "unintended acceleration" requirement to fix mats

- once the floor was perforated water from the wheels was blasted in.

The passenger side seems OK but I think a strip out and repaint will be needed sooner rather than later at least to check everything is OK and protected. I suspect there will be rust there but at an earlier stage.

Also behind the plastic wheel liners in the front wheel wells were something akin to a black diaper that was soaking wet. I removed these as they were up against the steel body.

Interestingly while stripping everything out of the footwell I found part of Toyota`s modifications to the accelerator - a piece of styrofoam duck taped to the floor under the carpet beneath the accelerator pedal! (can be seen in photo).

Hopefully this info might be useful for someone with a Camry or other vehicle potentially having these issues.
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45 replies
Deal Expert
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Jul 30, 2007
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Toronto
It looks like they don’t make them what they used to . Grinning Face With Smiling Eyes

I was expecting any Toyota would last a min. 50 yrs ☹️
Deal Expert
Jan 15, 2006
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Richmond Hill
Ducked taped styrofoam??? WTF LOL
[OP]
Deal Addict
Jan 8, 2009
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Ontario
EP32k2 wrote: Ducked taped styrofoam??? WTF LOL
I just googled it to find out if it should be there post accelerator pedal recall work.

I found the following which seems to confirm it is part of the dealer accelerator mods to address the "unintended acceleration" issues. So I guess I have to put it back! Will contact Toyota for instructions as surely duck tape is not reliable enough.

"The repair will involve the placement of a rubber stopper behind the accelerator, as well as a so-called tibia pad. This is a piece of hardened Styrofoam that sits between the metal floor pan and the carpet, just in front of the pedals".

http://www.thedetroitbureau.com/2010/03 ... nt-recall/

Looks like ordinary styrofoam to me.
Deal Fanatic
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Dec 28, 2007
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Alberta
Isn't that for starting and stopping the car like in the Flintstones? :) :) :)
[OP]
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Jan 8, 2009
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jackrabbit000 wrote: Isn't that for starting and stopping the car like in the Flintstones? :) :) :)
Would be handy when the regen braking cuts out going over potholes.
Deal Addict
Sep 8, 2017
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GTA
Is that photo how you found it? Or did you cut out some extra material?

When's the last time anybody inspected the underbody? Holes in the floor are usually pretty easy to spot.
Deal Fanatic
Jul 4, 2004
8681 posts
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Could be the same situation brewing that caused Toyota to replace the frames on their Tacoma pickup trucks, http://www.toyotaproblems.com/frame-rust/.

You should file a report with the the NHTSA in the US, https://www-odi.nhtsa.dot.gov/VehicleComplaint/ and Transport Canada, https://www.tc.gc.ca/en/services/road/d ... efect.html.
Help an animal charity or sanctuary out today. Become a volunteer, advocate, foster a pet, or donate. They need you as much as you need them!
[OP]
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Jan 8, 2009
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Ontario
derass wrote: Is that photo how you found it? Or did you cut out some extra material?

When's the last time anybody inspected the underbody? Holes in the floor are usually pretty easy to spot.
It was always main dealer serviced until this time when I got an oil change at Costco while buying tires and because of the wait for a dealership slot. They mentioned cracks in the plastic sill covers but nothing else but was not expecting any inspection so did it myself

I cut out a little extra where there were small remnants on the edges as there was no point in leaving small pieces (less than 1 inch maximum and heavily perforated/thinned and attached with compromised spot welds so easily removed.

Nothing solid was cut out and any larger fragments in the bin were pieces of the materials stuck to the metal
in a sound deadening material/rust/underseal sandwich. These pieces could be easily snapped by hand but looked solid to the eye. There was no visible hole on the right hand side before I started probing with a small pry bar after finding the hole on the left. I also found the smaller hole in front of the larger left hole when cleaning off the coatings for welding. It is less easy to see in the photo as there is another level of surface rusted steel underneath.
Jr. Member
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Aug 18, 2013
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Next door
I've always pulled out sound deadening materials in the fenders which you can see when you open the door. Last thing I wanted was an absorbent material full of salty water sitting next to a metal fender.
Deal Expert
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Apr 21, 2004
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Added the word "learnt" to my vocabulary lol.

Maybe it's not just the Camry corroding.
Deal Addict
Mar 22, 2004
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Thats why I bought weathertech floor mats. After 7 years my floor looks like day 1.
Sr. Member
Oct 21, 2006
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jackrabbit000 wrote: Isn't that for starting and stopping the car like in the Flintstones? :) :) :)
Haha that was my first thought when I saw op's pic.
[OP]
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Jan 8, 2009
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Ontario
alanbrenton wrote: Added the word "learnt" to my vocabulary lol.

Maybe it's not just the Camry corroding.
I am sure your brain is fine - its just the way its spelt in UK (or should I say spelled for your benefit).
Sr. Member
May 6, 2010
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Richmond Hill
buy Volvo next time, at least older ones, they don't rust
Banned
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Jul 17, 2008
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Toyota is best comrade! How dare you question the reliability and quality of japanese manufacturing! Pay that premium for japanese quality and don't ask questions! All other brands are shit and not worth it!

/s
Deal Guru
Feb 9, 2006
12160 posts
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Brampton
1. Toyota has always been known for shit metal. Especially floor pans. Same for Honda.

2. You did all that work you only took 1 picture and you did it with a potato and the potato was focused on the bottom of the steering wheel?
[OP]
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tebore wrote: 1. Toyota has always been known for shit metal. Especially floor pans. Same for Honda.

2. You did all that work you only took 1 picture and you did it with a potato and the potato was focused on the bottom of the steering wheel?
If you want to see more pictures of a hole in the floor you need to get out more (after Covid obviously). However if that is a hole that excites you I can send you more pics for your personal perusal.
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Sep 9, 2012
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Martin (deal addict) wrote: Am I a victim of Toyota using sub-standard Kobe steel? Will be looking deeper into this.

https://www.reuters.com/article/us-kobe ... SKCN1GI2OI

https://ca.topclassactions.com/lawsuit- ... ble-enough
It’s very likely that you do indeed have some level of sub-standard Kobe steel in your Camry. That said, it wasn’t necessarily used where yours rusted out. From the light reading I’ve done, it seems like the Kobe steel was used more often in body panels like doors, trunks, fenders and other parts. I’m not sure if they used it for the shell of the chassis or the floor pans - but they might have. It might be worth some research to see.

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