Front chassis rails

[BARNPOT2000]

Well, I've stated to install my new springs and shocks, but while I'm stuck in there I want to clean up any ugly rusty bits. The worst areas seem to be the two box chassis sections running front to back at the front of the car below the frunk. Not sure if subframe is the correct term. My questions are a) can they be simply unbolted to refurb, and b) will my car fall apart (or at least deform) if I remove them?
Its presently up on axle stands on the sill jacking points. Anyone removed these before?

[J88TEO]

Unbolt and refurb...car wouldn't fall apart. Done these myself.

[McMr2]

Well, I've stated to install my new springs and shocks, but while I'm stuck in there I want to clean up any ugly rusty bits. The worst areas seem to be the two box chassis sections running front to back at the front of the car below the frunk. Not sure if subframe is the correct term. My questions are a) can they be simply unbolted to refurb, and b) will my car fall apart (or at least deform) if I remove them?
Its presently up on axle stands on the sill jacking points. Anyone removed these before?

Did these last winter, simple enough job. From memory one of the bolts goes through the control arm and can be a bit of a fiddle to get back in. Be aware that once you start taking bits off and poking about you'll likely discover other areas that could do with being cleaned up! 

[J88TEO]

Did these last winter, simple enough job. From memory one of the bolts goes through the control arm and can be a bit of a fiddle to get back in. Be aware that once you start taking bits off and poking about you'll likely discover other areas that could do with being cleaned up! 

Like opening a can of worms! 

[McMr2]

Well, I've stated to install my new springs and shocks, but while I'm stuck in there I want to clean up any ugly rusty bits. The worst areas seem to be the two box chassis sections running front to back at the front of the car below the frunk. Not sure if subframe is the correct term. My questions are a) can they be simply unbolted to refurb, and b) will my car fall apart (or at least deform) if I remove them?
Its presently up on axle stands on the sill jacking points. Anyone removed these before?

Like opening a can of worms! 

I'm sorry for the quality of the pics, but before and after for comparison if it helps.

I used a wire brush to remove the loose stuff, then used some rust treatment fluid (Loctite, others are avalable!) on it before 2 coats of black hammerite.

[BARNPOT2000]

I'm sorry for the quality of the pics, but before and after for comparison if it helps.

I used a wire brush to remove the loose stuff, then used some rust treatment fluid (Loctite, others are avalable!) on it before 2 coats of black hammerite.

Nice work, did you treat the inside of the section at all or is it completely sealed?

[BARNPOT2000]

Did these last winter, simple enough job. From memory one of the bolts goes through the control arm and can be a bit of a fiddle to get back in. Be aware that once you start taking bits off and poking about you'll likely discover other areas that could do with being cleaned up! 

Thanks, yes, I've mentally prepared for the worst(haven't told the boss it might be a long job though) 😉.

[BARNPOT2000]

Like opening a can of worms! 

Hope there aren't too many worm "holes" though 😊.

[1979scotte]

Of you can get them off you're doing OK.
I've seen one or 2 that would be a PITA to even get started.

[BARNPOT2000]

Of you can get them off you're doing OK.
I've seen one or 2 that would be a PITA to even get started.

I'm under the car now...it's been "challenging", Just about to remove the wishbone, not sure if the encapsulated nut is still viable in the chassis yet, dare not look atm. 😕

[McMr2]

Nice work, did you treat the inside of the section at all or is it completely sealed?

Only the outside, no easy way to get inside them.

[BARNPOT2000]

Just a few pics of progress so far. Chassis section are cleaning up well. By the way does anyone have the correct torque values to reinstall the chassis box sections please?
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[Joesson]

@BARNPOT2000
The after pictures are looking much better than the before. Are those new control arms that I see being treated to an extra coat of paint or the OE with new bushes etc?

[BARNPOT2000]

@BARNPOT2000
The after pictures are looking much better than the before. Are those new control arms that I see being treated to an extra coat of paint or the OE with new bushes etc?

They are yaris new ones, as you say getting an extra coating. The rust looks worse than it is really, just got under the paint, but very little "scaly" rust pitting. Touch wood I've been lucky with the bolts undoing pretty well, long may it continue 🙏. Might get some Bilt Hamber UB underbody wax on the underside before I start reassembling. The rustiest bit left up front is the abs pump support bracket, does anyone know if it can be removed and keep the abs all intact? I really don't want to start doing the brakes just yet 🙄.

[McMr2]

Just a few pics of progress so far. Chassis section are cleaning up well. By the way does anyone have the correct torque values to reinstall the chassis box sections please?
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Looking fresh

[J88TEO]

Great work!
When your are done with yours, mind coming over and do mine?...beer and BBQ on me!

[BARNPOT2000]

Great work!
When your are done with yours, mind coming over and do mine?...beer and BBQ on me!

You are very generous, if you were a bit closer I would be happy to come and help  . It
might involve board and lodgings for several days though, you cant rush paint drying time ... . Please bear in mind I haven't put it back together yet, still room for a disaster  .

[puma2]

  fair play when you take a job like this when done just looks so much better worth taking your time over and not to rush  

looks good for sure  

[BARNPOT2000]

fair play when you take a job like this when done just looks so much better worth taking your time over and not to rush  

looks good for sure  

Thanks, I wish it was a quick fix as I am not the most patient of people. I'm trying to hold myself back from throwing it back together as quickly as possible. I keep telling myself that I don't want to do this job again for many years to come....Thing is once you start taking bits off to clean up, other bits start shouting "me too" .Also when things are removed it makes getting to those awkward places so much easier so may as well do what I can. You never know the car may go up in value!! It would be the first car that I have owned that did that . This is just the front of course....subframe and suspension upgrade due shortly on the rear end...

[Joesson]

The rustiest bit left up front is the abs pump support bracket, does anyone know if it can be removed and keep the abs all intact? I really don't want to start doing the brakes just yet 🙄.

I managed to remove what was left of the Support Bracket  with the system intact.
The bottom of the bracket, a tray like piece was rusted away, I formed a new "tray" using a part of an old aluminium baking tray and pop riveted it to the rest of the steel bracket.
Just don't anyone say anything about dissimilar metals!

[Call the midlife!]

They are yaris new ones, as you say getting an extra coating. The rust looks worse than it is really, just got under the paint, but very little "scaly" rust pitting. Touch wood I've been lucky with the bolts undoing pretty well, long may it continue 🙏. Might get some Bilt Hamber UB underbody wax on the underside before I start reassembling. The rustiest bit left up front is the abs pump support bracket, does anyone know if it can be removed and keep the abs all intact? I really don't want to start doing the brakes just yet 🙄.

You can remove the ABS bracket without dismantling any of the pipes etc if you drop the steering rack, otherwise you can't get it low enough to turn and pull out.
It also helps if you gently modify the angle of the bracket arms...

[BARNPOT2000]

You can remove the ABS bracket without dismantling any of the pipes etc if you drop the steering rack, otherwise you can't get it low enough to turn and pull out.
It also helps if you gently modify the angle of the bracket arms...

Thanks, I will give it a go.....

[Alex Knight]

A friend of mine made one for me, as Toyota have discontinued the bracket I think? Or it may have been a gazillion pounds from Mr T.

Either way, it's stainless steel. Should last a lot longer than the OEM part!

[BARNPOT2000]

Did these last winter, simple enough job. From memory one of the bolts goes through the control arm and can be a bit of a fiddle to get back in. Be aware that once you start taking bits off and poking about you'll likely discover other areas that could do with being cleaned up! 

Just on the verge of reinstalling the chassis box sections, do you remember what torque the bolts should be tightened up to please? I believe the long one through the wishbone bush is 73 Nm so maybe do all up about the same?

[Joesson]

Just on the verge of reinstalling the chassis box sections, do you remember what torque the bolts should be tightened up to please? I believe the long one through the wishbone bush is 73 Nm so maybe do all up about the same?

Can't help with a specific value but this may help:
https://www.engineeringtoolbox.com/metric-bolts-maximum-torque-d_2054.html