Bulletins
| Bulletin | Bulletin date | Replacement Bulletin | Item no. | Summary | Added |
|---|---|---|---|---|---|
| STRUCTURE - BODY | |||||
| 00304 | 08/03/2004 | 10009544 | Bedliner tailgate panel may warp/distort at elevated temperatures. *tt | 10/06/2004 | |
Investigations
| NHTSA ID | Manufacturer | Date open | Date close | Subject | Recall campaign | |
|---|---|---|---|---|---|---|
| STRUCTURE - FRAME AND MEMBERS | ||||||
| PE09049 | TOYOTA MOTOR NORTH AMERICA, INC. | 10/06/2009 | 01/26/2010 | FRAME CORROSION | 09V444000 | |
| This investigation was opened based on 20 reports of model year (my) 2000 and 2001 vehicles experiencing severe corrosion of the frame, resulting in either under-body mounted spare tire separation or rear brake failure.the failure report counts shown above are for my 2000 and 2001 vehicles only.by letter of november 16, 2009 toyota has notified the agency that it will conduct a safety recall (09v-444) of approximately 110,000 model year (my) 2000 through 2003 tundra vehicles.the affected recalled vehicles were sold or are currently registered in the district of columbia and the states of ct, de, il, in, ky, ma, md, me, mi, mn, nh, nj, ny, oh, pa, ri, va, vt, wi, wv.toyota alleges high amounts of road salts are used in these areas and excessive corrosion of the rear cross-member (to which the spare tire is mounted) can occur and cause the spare tire to separate from the vehicle and can also lead to rear brake failure.toyota stated: toyota has tentatively concluded that the root cause is a combination of factors, including usage in areas where road salt is applied, inadequate vehicle maintenance (i.e., not following the recommendations in the owner's manual), the design of the rear cross-member, and manufacturing issues.the design of the rear cross-member is such that it is open on the top side and susceptible to accumulation of dirt, water and road salt.manufacturing issues of the rear cross-member related to the coating process also affect its corrosion resistance.toyota also states that owners of my 2000 through 2003 vehicles in states not covered by the recall will be notified on how to obtain the same inspection and repair as the recalled vehicles, free of charge.further toyota states: please note that while toyota has not determined a defect exists in 2004 through 2006 my tundra vehicles, toyota plans on initiating a field action in the near future to prevent future corrosion on those vehicles originally sold or currently registered in the affected region at no cost to the owner.by letter of january 8, 2010 toyota has notified the agency that it amended its defect information report for safety recall 09v-444 to include the fuel tank mounting system (i.e., fuel tank support straps and fuel tank mounting cross-members) in the safety recall.toyota states: toyota has not decided that the fuel tank mounting system in those vehicles contains a safety-related defect within the meaning of federal motor vehicle safety law.rather, toyota is taking this action at odi's request and to avoid future disagreement with odi with respect to this issue.my 2007 and newer tundra vehicles are not included in any of toyota's actions as the rear cross-member in those vehicles have been redesigned so that it is open on the bottom.the actions taken by toyota are sufficient to resolve the issues raised by this investigation.accordingly, this investigation is closed.the closing of this investigation does not constitute a finding by nhtsa that a safety-related defect does not exist in the subject vehicles.the agency will take further action if warranted by the circumstances. | ||||||
| PE09049 | TOYOTA MOTOR CORPORATION | 10/06/2009 | 01/26/2010 | FRAME CORROSION | 09V444000 | |
| This investigation was opened based on 20 reports of model year (my) 2000 and 2001 vehicles experiencing severe corrosion of the frame, resulting in either under-body mounted spare tire separation or rear brake failure.the failure report counts shown above are for my 2000 and 2001 vehicles only.by letter of november 16, 2009 toyota has notified the agency that it will conduct a safety recall (09v-444) of approximately 110,000 model year (my) 2000 through 2003 tundra vehicles.the affected recalled vehicles were sold or are currently registered in the district of columbia and the states of ct, de, il, in, ky, ma, md, me, mi, mn, nh, nj, ny, oh, pa, ri, va, vt, wi, wv.toyota alleges high amounts of road salts are used in these areas and excessive corrosion of the rear cross-member (to which the spare tire is mounted) can occur and cause the spare tire to separate from the vehicle and can also lead to rear brake failure.toyota stated: toyota has tentatively concluded that the root cause is a combination of factors, including usage in areas where road salt is applied, inadequate vehicle maintenance (i.e., not following the recommendations in the owner's manual), the design of the rear cross-member, and manufacturing issues.the design of the rear cross-member is such that it is open on the top side and susceptible to accumulation of dirt, water and road salt.manufacturing issues of the rear cross-member related to the coating process also affect its corrosion resistance.toyota also states that owners of my 2000 through 2003 vehicles in states not covered by the recall will be notified on how to obtain the same inspection and repair as the recalled vehicles, free of charge.further toyota states: please note that while toyota has not determined a defect exists in 2004 through 2006 my tundra vehicles, toyota plans on initiating a field action in the near future to prevent future corrosion on those vehicles originally sold or currently registered in the affected region at no cost to the owner.by letter of january 8, 2010 toyota has notified the agency that it amended its defect information report for safety recall 09v-444 to include the fuel tank mounting system (i.e., fuel tank support straps and fuel tank mounting cross-members) in the safety recall.toyota states: toyota has not decided that the fuel tank mounting system in those vehicles contains a safety-related defect within the meaning of federal motor vehicle safety law.rather, toyota is taking this action at odi's request and to avoid future disagreement with odi with respect to this issue.my 2007 and newer tundra vehicles are not included in any of toyota's actions as the rear cross-member in those vehicles have been redesigned so that it is open on the bottom.the actions taken by toyota are sufficient to resolve the issues raised by this investigation.accordingly, this investigation is closed.the closing of this investigation does not constitute a finding by nhtsa that a safety-related defect does not exist in the subject vehicles.the agency will take further action if warranted by the circumstances. | ||||||
Consumer Complaints
| Fail date | miles | occurences | Purchase date |
|---|---|---|---|
| STRUCTURE | |||
| 09/07/2012 | 62900 | 1 | |
| Excessive rust throughout underbody and drive train components. porous, rusted through differential now leaking oil. rust issues started while vehicle still under 3/36 warranty. belt tensioner bracket, bracket mount and ball joints at 33,921 miles, sway bar linkages rusted through at 45,168 miles. both issued repaired as warranty matters. toyota claims current problem not covered but admits defective material and offers to provide replacement parts only, requiring estimated $770 to complete the repair. have initiated complaint with toyota, file number available upon request. *tr | |||
| 03/03/2011 | 140000 | ||
| Kelson chu, the owner of toyota 2004 tundra vehicle id 5tbrn34194s444373 for toyota case #1103071079. as reported to the toyota customer experience center (center) on march 7, 2011, mr. chu and his vehicle were involved in a very frightening and traumatic incident on march 3rd. the front arm, joint, and wheel of the vehicle suddenly broke apart and fell off the vehicle while driving 65 mph on the highway. with other drivers watching, mr. chu was able to control and maneuver this crippled vehicle 2,000 feet - from the inner most lane to the shoulder of the road without causing injury to him and others, drivers/vehicles. as stated by the police at the scene and others witnessed the incident, it was simply a | |||
| STRUCTURE - BODY | |||
| 11/15/2012 | 157000 | ||
| Tl* the contact owns a 2004 toyota tundra. the contact stated that while replacing the front passenger side tire, it was noticed that approximately six inches of the frame was extremely rusted. the manufacturer was not made aware of the failure. the vehicle was not repaired. the approximate failure mileage was 157,000. the vin was not available. | |||
| 11/15/2012 | 157000 | ||
| Tl- the contact owns a 2004 toyota tundra. the contact stated that while replacing the front passenger side tire, it was noticed that approximately six inches of the frame was extremely rusted. the manufacturer was not made aware of the failure. the vehicle was not repaired. the approximate failure mileage was 157,000. the vin was not available. mah | |||
| 11/15/2012 | 157000 | ||
| Tl- the contact owns a 2004 toyota tundra. the contact stated while replacing the front passenger side tire he noticed that approximately six inches of the frame was extremely rusted. the manufacturer was not made aware of the failure. the vehicle was not repaired. the vin was not available. the approximate failure mileage was 157,000. da | |||
| 03/10/2010 | 30000 | ||
| Tl* the contact owns a 2004 toyota tundra. the contact stated that the entire frame exhibited severe flaking rust, which separated in chunks. the corrosion became progressively worse over a period of time. the vehicle was inspected by an authorized dealer who stated that the frame rusted without any perforation. the vehicle was not repaired. the manufacturer was notified of the problem. the approximate failure mileage was 30,000. | |||
| 03/10/2010 | 30000 | ||
| Tl-the contact owns a 2004 toyota tundra. the contact stated that the entire frame exhibited severe flaking rust, which separated in chunks. the corrosion became progressively worse over a period of time. the vehicle was inspected by an authorized dealer who stated that the frame rusted without any perforation. the vehicle was not repaired. the manufacturer was notified of the problem. the approximate failure mileage was 30,000. kmj | |||
| 03/10/2010 | 30000 | ||
| Tl-the contact owns a 2004 toyota tundra. the contact noticed that the entire frame exhibited severe flaky rust which separated in chunks. the corrosion became progressively worse over a period of time. the vehicle was inspected by an authorized dealer who stated the frame had rusted without any perforation. the vehicle had not been repaired. the manufacturer was notified of the problem. the approximate failure mileage was 30,000. js | |||
| 12/30/2012 | 62000 | ||
| Tl-the contact owns a 2004 toyota tundra. the contact stated that oil was leaking from under the vehicle. the contact took the vehicle to a local mechanic where the mechanic stated that the rear differential house exhibited excessive rust. the mechanic also advised the contact that the vehicle was unsafe to drive. the contact called the manufacturer regarding the excessive rust issue however, the manufacturer provided no assistance. the failure mileage was 62,000. kmj | |||
| 01/01/2011 | 80000 | ||
| Tl-the contact owns a 2004 toyota tundra. the contact stated that the spare tire fell from the vehicle due to the carrier being rusted. in addition, he noticed that the frame was severely rusted. the vehicle was taken to a dealer where they advised him that the carrier was rusted and needed to be replaced. also, the frame was not completely corroded. the vehicle was not repaired. the manufacturer was contacted and offered no assistance. the failure mileage was approximately 80,000. the current mileage was approximately 123,000. kmj | |||
| 12/30/2012 | 62000 | ||
| Tl-the contact owns a 2004 toyota tundra. the contact stated gear oil leaking underneath the vehicle so the contact took the vehicle to a local mechanic. the mechanic stated the rear differential house had excessive rust. the mechanic stated the vehicle was unsafe to drive. the contact called the manufacturer regarding the excessive rust. the manufacturer stated their was nothing they could do to the vehicle. the failure mileage was 62,000. jo | |||
| 01/01/2011 | 80000 | ||
| Tl-the contact owns a 2004 toyota tundra. the contact stated that the spare tire fell from the vehicle due to the carrier being rusted. in addition, he noticed that the frame was severely rusted. the vehicle was taken to a dealer where they advised him that the carrier was rusted and needed to be replaced. also, the frame was not completely corroded. the vehicle was not repaired. the manufacturer was contacted and offered no assistance. the failure mileage was approximately 80,000. the current mileage was approximately 123,000. kmj | |||
| 01/01/2011 | 80000 | ||
| Tl-the contact owns a 2004 toyota tundra. the contact stated that after checking his vehicle he saw that his spare tire was no longer on the vehicle due to the rusting of the carrier. in addition, he noticed that his frame was severely rusted as well. the vehicle was taken to a dealer. after diagnosis they advised him that the carrier was rusted and needed to be replaced and that the frame was not rotted completely through. the vehicle was not repaired. the manufacturer was contacted and they offered no assistance. the failure mileage was approximately 80,000. the current mileage was approximately 123,000. tb | |||
| 12/21/2010 | 55000 | ||
| Tl- the contact owns a 2004 toyota tundra. the contact stated that the frame was severely rusted and could possibly fracture in half at any time. the vehicle was taken to the dealer for diagnosis however, the vehicle was not repaired. the manufacturer was notified but offered no assistance. the vehicle was not repaired. the vin was unavailable. the failure and current mileage was 55,000. kmj | |||
| 12/21/2010 | 55000 | ||
| Tl- the contact owns a 2004 toyota tundra. the contact stated that the frame of his vehicle was so badly rusted it could have broken in half at any moment. the vehicle was taken to the dealer for diagnosis and there was an attempt to get a new frame for the vehicle but the manufacturer denied the request. the manufacturer was notified but offered no assistance. the vehicle had not been repaired. the vin was unavailable. the failure and current mileage was 55,00. dt | |||
| 12/12/2012 | 48000 | 1 | |
| My 2004 tundra has a rusted frame that is not safe. the truck has 48,000 miles on it and the frame has rust holes through it. this is not normal surface rust. the truck has no other rust issues. toyota needs to recall this vehicle. *tr | |||
| 12/12/2012 | 48000 | ||
| My 2004 tundra has a rusted frame that is not safe. the truck has 48,000 miles on it and the frame has rust holes through it. this is not normal surface rust. the truck has no other rust issues. toyota needs to recall this vehicle. | |||
| 11/18/2009 | 113369 | ||
| Tl-the contact owns a 2004 toyota tundra. the contact stated that the frame exhibited an excessive amount of rust that was surrounding the rear tires and the fuel tank. the contact did not take the vehicle to a dealer or mechanic for inspection. the contact called the manufacturer regarding the rust issue and the manufacturer advised the contact that rust was not covered under any specific recall. the vehicle was not repaired. the failure mileage was 113,369. kmj | |||
| 09/01/2012 | 130000 | ||
| Tl- the contact owns a 2004 toyota tundra. the vehicle was taken to an independent mechanic for unrelated repairs when the mechanic informed the contact that the entire frame was corroded. the manufacturer was made aware of the failure and a complaint was filed. the vehicle was not repaired. the approximate failure mileage was 130,000. kmj | |||
| 06/11/2012 | 50166 | ||
| Tl-the contact owns a 2004 toyota tundra. the contact stated that he noticed a stain in his driveway and took the vehicle to a personal mechanic for a diagnosis. the contact was informed that the rear differential had completely rusted out and was leaking fluid. the vehicle was taken to the dealer for inspection. the dealer acknowledged that there was an issue, but offered no assistance. the manufacturer was notified but offered no assistance. the vehicle had not been repaired. the failure and current mileages were 50,166. sm. | |||
| 06/11/2012 | 50166 | ||
| Tl- the contact owns a 2004 toyota tundra. the contact stated that he noticed a stain in his driveway and took the vehicle to a personal mechanic for diagnosis. he was informed that the rear differential had completely rusted out and was leaking fluid. the vehicle was taken to the dealer for inspection. the dealer acknowledged there was an issue but offered no assistance. the manufacturer was notified but offered no assistance. the vehicle had not been repaired. the failure and current mileages were 50,166. dt | |||
| 07/15/2009 | 1 | ||
| My 2004 toyota tundra double cab has an excessive amount of rust on the undercarriage. because of this rust, the camber bolts cannot be removed to properly align the vehicle. i have been told that they will have to use heat to remove them, along with a lot of force, and in turn may do frame damage in the process. i have been quoted by my dealer $5,200 to fix the problem which initially started with a small shimmy in the steering wheel which grew into a big shimmy especially while towing. that quote does not include any possible charged from the body shop if damage to the frame should occur. i do not have $5,200 so i ended up with a new set of tires and half of an alignment because the camber bolts were not able to be removed. here i am months later and my new tires are so bald on the front that i am actually seeing the tread showing through. i have always loved my tundra, but all of this rust on the frame and undercarriage is very concerning regarding the longevity of my vehicle. i was told that toyotas last forever. at this point i feel that my truck is dangerous to even drive but it is my only vehicle. i have owned and maintained many vehicles and never had rust issues like this, nor have i ever been faced with such a costly repair on a not so old vehicle. i am stuck in a bad place and just don't know where to go or what to do. i desperately need my truck. without it i lose my source of transportation as well as my ability to earn a living. i just simply cannot afford... meaning i just do not have this kind of money to bring my truck back to health. all of this stress and frustration is a result of this excessive rust. included in the estimate is remove and replace camber bolts $1,957 --- steering rack boots 400.00 alignment 90.00---- driveshaft assembly $2,003---- rear u-joint $433.00---- differential fluid $330.00 it does not include any possible damage to the frame/body in their attempt to remove the camber bolts or another brand new set of tires. *tr | |||
| 04/15/2009 | 43741 | 1 | |
| Vehicle frame and undercarriage seems to have an excessive amount of rust and deterioration. as i perform maintenance on the vehicle, i am replacing rusted parts including bolts, drain plugs as well as spraying the undercarriage with wd-40, 3m undercoating spray and corrosion stop. this issue is an on-going fight to keep the rust at bay. *tr | |||
| 07/19/2004 | 2700 | 1 | 04/29/2004 |
| Sun roof exploded and glass fell inside of vehicle. also, damaged outside of cab and hard cover on bed of truck. the temperature was 79 degrees and there were no vehicles or obstackles around to have caused this problem.*ak | |||
| STRUCTURE - BODY - TAILGATE - HINGE AND ATTACHMENTS | |||
| 07/17/2008 | 65269 | 1 | |
| There are two cables that hold the tailgate in place when fully opened(extended). yesterday(7/17/08) while unloading my motorcycle, both cables broke simultaneously mid way through the unloading process. the cables broke at the exact same place which was exactly half way from one end to the other. the cable is enclosed in a plastic sleeve. that sleeve is not sealed at each end. when the tailgate is in the closed position, which is most of the time, rain or other moisture collects in the plastic enclosure and settles at the bottom of the u shaped tube. over time that moisture has caused the cables to rust and weaken thus the break in my opinion. the result of the brake was that the tailgate feel unannounced to the top of the bumper thus denting the bumper and potentially causing harm to the individual who was doing the unloading. in my opinion this is a flawed product. *tr | |||
| STRUCTURE - FRAME AND MEMBERS | |||
| 08/09/2011 | 83605 | ||
| Our 2004 toyota tundra has such excessive rust on the undercarriage that the rear axle housing which holds the gears has rusted through, causing fluid to leak. toyota says there is nothing that can be done for us. | |||
| 03/16/2010 | 95250 | ||
| I own a 2004 toyota tundra pickup truck. the bottom of the truck in the rear has rusted and the shock mount broke off. the piece that broke off also has the brake lines attached. this can potentially lead to the lines snapping and failing. i saw a recall on this for 2000 to 2003 years but not for 2004. the problem identified in the recall is the exact problem i am having. i am also concerned that the mount for the spare tire will continue to rust and fall off. | |||
| 07/15/2009 | 1 | ||
| My 2004 toyota tundra double cab has an excessive amount of rust on the undercarriage. because of this rust, the camber bolts cannot be removed to properly align the vehicle. i have been told that they will have to use heat to remove them, along with a lot of force, and in turn may do frame damage in the process. i have been quoted by my dealer $5,200 to fix the problem which initially started with a small shimmy in the steering wheel which grew into a big shimmy especially while towing. that quote does not include any possible charged from the body shop if damage to the frame should occur. i do not have $5,200 so i ended up with a new set of tires and half of an alignment because the camber bolts were not able to be removed. here i am months later and my new tires are so bald on the front that i am actually seeing the tread showing through. i have always loved my tundra, but all of this rust on the frame and undercarriage is very concerning regarding the longevity of my vehicle. i was told that toyotas last forever. at this point i feel that my truck is dangerous to even drive but it is my only vehicle. i have owned and maintained many vehicles and never had rust issues like this, nor have i ever been faced with such a costly repair on a not so old vehicle. i am stuck in a bad place and just don't know where to go or what to do. i desperately need my truck. without it i lose my source of transportation as well as my ability to earn a living. i just simply cannot afford... meaning i just do not have this kind of money to bring my truck back to health. all of this stress and frustration is a result of this excessive rust. included in the estimate is remove and replace camber bolts $1,957 --- steering rack boots 400.00 alignment 90.00---- driveshaft assembly $2,003---- rear u-joint $433.00---- differential fluid $330.00 it does not include any possible damage to the frame/body in their attempt to remove the camber bolts or another brand new set of tires. *tr | |||
| 09/02/2009 | 65000 | 1 | |
| 2004 toyota tundra double cab had severe rusting which caused the emergency brake cable and pin attachments to break. when the dealer fixed the brake, i was told that the problem was caused by very rusted parts which then led me to discover that the entire frame of the truck is heavily rusted. dealer called it flaking. i contacted toyota and the dealer was instructed to inspect the truck and send results to toyota. they now call it surface rust. i asked the dealer to put in writing that the truck was safe but they did not. i am now concerned that with the frame, bolts, nuts and joints so rusty it will soon become a safety issue. i have looked at other tundra's the same age and the undercarriage appears to have an undercoating that i do not. i am not satisfied with the answer that toyota has given me which states that it is only surface rust. *tr | |||
| 09/13/2009 | 85000 | 1 | |
| Frame rust. *tr | |||
| 04/15/2009 | 43741 | 1 | |
| Vehicle frame and undercarriage seems to have an excessive amount of rust and deterioration. as i perform maintenance on the vehicle, i am replacing rusted parts including bolts, drain plugs as well as spraying the undercarriage with wd-40, 3m undercoating spray and corrosion stop. this issue is an on-going fight to keep the rust at bay. *tr | |||
| STRUCTURE - FRAME AND MEMBERS - UNDERBODY SHIELDS | |||
| 02/07/2013 | 68000 | 1 | |
| Noticed extreme rust on frame and other metal parts flaking and falling off. condition appears unsafe to drive. tr | |||
| 12/12/2012 | 67500 | 1 | |
| Severe frame rust. will not pass inspection. local dealer took pictures and forwarded them to local field rep. toyota has recalled tundras from 2000 to 2003 for this same problem, replacing the frames. my vehicle, although a 2004 model, was assembled in december of 2003. *tr | |||
| 12/03/2012 | 1 | ||
| 2004 toyota tundra. consumer writes in regards to frame rust. *tgw the consumer stated there is currently a recall for the 2001-2003 later models. *jb | |||
| 10/18/2012 | 107400 | 1 | |
| My vehicle needs an alignment. i was told by the toyota dealership that the frame on my vehicle is rusted and needs to be replaced. toyota tundras do have a recall for the rusted frame but my vehicle isn't part of this recall since its 3 months newer. i was told by the toyota service rep at the dealership that my vehicle is unsafe to drive. i contacted toyota and they claim that they cannot do anything about this. *tr | |||
| 10/08/2012 | 45000 | 1 | |
| I had the check engine lite checked at the toyota dealer. the tundra required a complete exhaust system including catalytic converters at a cost of $4000.00. the dealer found that the frame was rusted through and notified toyota. toyota will pay to replace the frame. however the 2004 model year is not part of a recall. *tr | |||
| 08/23/2012 | 147526 | 1 | |
| During the course of routine service at independent garage mechanic pointed out three major components with severe corrosion issues that need to be addressed immediately: 1) frame severely rotted by rust, a perforation was identified on front driver's side 2) rear axle body severely corroded by rust, not leaking yet but likely will soon 3) power steering rack severely rotted by rust on passenger side, not leaking yet but likely will soon, described by mechanic as tender failure of any of these items could cause an accident leading to serious injury. *tr | |||
| 08/06/2012 | 44318 | 1 | |
| The 2003 tundra have reported frame rust the 2004s are the same we need help in getting toyota to do something they are good trucks an mine can be fixed if it is done early the rust is falling off in my driveway this is a real problem so if we owners can get help from the gov. to get this addressed thank you. *tr | |||
| 04/15/2012 | 109000 | 1 | |
| Rear end leaking oil. mechanic able to put finger through housing due to severe rusting. entire rear end replaced under extended warranty i purchased. entire frame rusted heavily. all welds severely rusted. frame integrity gone. front arm rusted so badly mechanic says it will not pass inspection in october, 2012. front arm so rusted it is likely to collapse. emergency brake not functioning due to heavy corrosion...advised to replace. body immaculate. no rust anywhere but frame. *tr | |||
| 07/03/2008 | 100742 | 1 | |
| Extensive rust is located on the frame of the truck. this 2004 toyota tundra was built on the toyota tacoma frames before toyota made the larger tundra and frames. it's therefore likely that the same extensive rust recall for the previous years tacoma's should extend to the tundra's that were once built on these frames. since the delivery date on this truck is december 31, 2003, it is believed that this vehicle should also be recalled under the same premise. the pictures from the recalled tacoma frames look very, very similar and there should be a check on whether or not this 2004 toyota tundra frame has the same exact problem. *tr | |||