I have an '04 Doublecab that has been in Michigan all it's life. It just rolled 156K. I took it in when I got the notice about the buy-back/replacement/coating (2008 was it?). Mine got the coating since it was in good shape at the time. The coating has been flaking off over the years and I have had them inspect it periodically (I think a mech would just give it a look-over). Well, I now have a serious medical issue, polycystic kidney disease. I have to get a transplant in the near future. I decided to give Toyota a call and see what they would say about me coating the frame again with something like POR15. I don't want to have a truck fall apart while I am recovering. The guy I spoke with told me to take it into my dealer and have them inspect it and have them produce a paper saying it passed (I have not poked at it just out of fear of repercussions). I did so last Thursday. The head service writer has been there since I bought the truck in '05 and has always been helpful and is familiar with my truck. I spoke with Mat about my situation. He promptly took it back to a service bay to inspect it. About 20 minutes later he came back and told me it failed and I am getting a new frame. He said that it should be in in about a couple weeks and don't go too crazy with the truck for safety reasons. He said that it should take about a week to do but I don't have my hopes that high. They had my buddy's Tundra almost 3 months but he told them to take their time since he couldn't drive due to a surgery. He said it rides like new now at least.
I am glad that Toyota stood behind the truck even several years later. My nephew bought a ;01 XtraCab last summer and I was jealous how his had a nice frame under it!