2004 Toyota Tundra suspension problems

SUSPENSION

The contact owns a 2004 Toyota Tundra. The contact stated that while driving approximately 40 MPH, there was an abnormal screeching sound coming from the vehicle. The contact then saw sparks coming from the rear driver’s side of the vehicle, and the driver’s side rear wheel was turned sideways. The vehicle was pulled over to the shoulder and was later towed back to the residence. The vehicle was taken to an independent mechanic, and the contact was informed that the ball joint, control arms, front suspension, and several other unknown parts needed to be replaced. The vehicle was repaired; however, the failure persisted. The independent mechanic made the contact aware of an unknown NHTSA Campaign Number; however, the VIN was not under recall. The manufacturer was notified of the failure. The failure mileage was approximately 200,000.

NHTSA complaint #11718541 — an unverified report by a vehicle owner.

SUSPENSION

The warranty work done on the frame of my Tundra that has since failed. The Bracket holding my SwayBar has broken off the frame and, more importantly, the frame has rusted to the point where there is now a hole in it. These are areas where the warranty work occurred.

NHTSA complaint #11578237 — an unverified report by a vehicle owner.

SUSPENSION

This truck has a frame that is rusting out. It has rust holes and is now unsafe to drive.

NHTSA complaint #11578243 — an unverified report by a vehicle owner.

SUSPENSION

The contact owns a 2004 Toyota Tundra. The contact stated while driving 25 MPH, the front driver's side lower ball joint detached, causing the driver's side wheel to separate from the vehicle, and the vehicle lowered to the ground. The vehicle was towed to the residence, where it was diagnosed by an independent mechanic. The mechanic determined that the front driver's side lower ball joint needed to be replaced. The mechanic replaced the front driver's side and passenger's side lower ball joints. The contact stated that the vehicle was previously repaired by an unknown dealer for the same failure. The contact stated that the front driver's side and passenger's side ball joints failed several times while driving and were replaced; however, the failure persisted. Additionally, the contact stated while driving approximately 60-65 MPH, the driver's side ball joint failed, which damaged the running board, the brakes, the driver's side door, the tie rod, the coil springs, the lower control arm, and the lower and upper ball joints. The vehicle skidded to the side of the road. The vehicle was towed to the residence. The contact related the failure to NHTSA Campaign Number: 05V225000 (Suspension), 07V013000 (Suspension) and 22E002000 (Suspension); however, the VIN was not included. The dealer was notified of the failure. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was approximately 140,000.

NHTSA complaint #11542934 — an unverified report by a vehicle owner.

SUSPENSION

Severe rust to the frame of my 2004 Toyota Tundra SR5 double cab. There are holes through the frame. Took it for an oil change and the mechanic told me to be careful. Crawled under the truck and couldn't believe how bad it was.

NHTSA complaint #11537588 — an unverified report by a vehicle owner.

SUSPENSION

Informed by Al Serra at 4200 Bay Rd in Saginaw, MI 48603 that there are holes present in the frame that pose a dire safety concern. This is a known issue with this model year, but Toyota says the recall is no longer valid.

NHTSA complaint #11531577 — an unverified report by a vehicle owner.

SUSPENSION

The contact owns a 2004 Toyota Tundra. The contact stated that while driving at various speeds, the vehicle was pulling to the right. The vehicle was taken to the local dealer who performed a wheel alignment, but the failure persisted. The cause of the failure was not yet determined. The local dealer and manufacturer were not yet notified of the failure. The failure mileage was 100,000.

NHTSA complaint #11494897 — an unverified report by a vehicle owner.

SUSPENSION

Purchased new Toyota Tundra in 2004. Performed rust recall at dealer on 07/22/15. October 2016, brakes failed. Brake line completely rusted. July 26, 2021, Toyota Tundra rejected at state inspection for badly rusted frame. Inspectors were unable to get wheel off to inspect brakes because of rust damage. Took to Toyota dealer on March 9, 2022. They performed airbag recall. Unable to do front suspension lower ball joints recall. Dealer said frame could break when they put it on lift. Dealer said Timeframe to repair frame had expired. Estimate to fix frame over $15,000; Plus would need a lot more parts to go with replacement. Vehicle has approximately 68,500 miles on it.

NHTSA complaint #11481230 — an unverified report by a vehicle owner.

SUSPENSION

My 2004 Tundra has a rusted frame and is presently not drivable. No recall notice was send to me by Toyota, nor were any subsequent calls or mail sent. I have 75k on this truck and want Toyota to honor their safety recall

NHTSA complaint #11463010 — an unverified report by a vehicle owner.

SUSPENSION

The frame on my truck is rusted into ,unsafe for road use, Toyota refuses to repair or replace the frame. It was reported in 2017 under a recall,

NHTSA complaint #11453756 — an unverified report by a vehicle owner.

SUSPENSION

Brought vehicle in for service and frame is completely rusted through in critical areas where suspension and body mounts are supposed to be mounted. The car is not road worthy and unsafe to drive. I came to understand that there was a recall for these truck frame, however my frame was never replaced. My frame was never treated for rust. This truck has always been maintained and serviced at a Toyota dealership. Now I'm told their is nothing they can do.

NHTSA complaint #11437799 — an unverified report by a vehicle owner.

SUSPENSION

I had the dealer take my truck in for the frame recall. I asked for them to replace the frame because I was not comfortable with how they were handling it. Per the service record they filled in perforations and “undercoated. I did not believe that filling in existing perforations was the safest way to handle this. After brining the truck to a shop to check the steering we were told that they wouldn’t even put it up on a lift. The steering issue was that the rack and pinion steering was literally falling out due to the rusted frame. We drove this vehicle home and parked it. About a week later the spare tire fell out right onto our driveway. Needless to say, I am certain there are many more Toyota trucks out there ready to fall apart on the road. We contacted Toyota corporate several times to try to rectify this mishandling of our recall. We called and sent certified letters. We asked to share the cost of a new frame and they said no. We then had the truck towed to a shop who could do the work. They ordered a frame from Toyota only to be contacted 2 months later saying that the frame was discontinued and they wouldn’t be sending it after all (we were willing to pay fir the frame and install because we had a useless and UNSAFE vehicle. We finally found a shop over an hour away who could rebuild/fabricate the frame and replace the fallen out steering etc. we had that truck towed about 60 miles away to have this work completed. This mishandling of the recall by Toyota and their lack of customer care cost me a whopping $17,000! Again, unsafe Tundras out there for sure. Please advise…this is the 2nd time I’ve filled out this form and never heard anything. Thank you in advance. [XXX] INFORMATION Redacted PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).

NHTSA complaint #11418635 — an unverified report by a vehicle owner.

SUSPENSION

TL* THE CONTACT OWNS A 2004 TOYOTA TUNDRA. THE CONTACT STATED THAT UPON TAKING HIS VEHICLE TO HERITAGE TOYOTA (1620 SHELBURNE RD, SOUTH BURLINGTON, VT 05403) FOR NHTSA CAMPAIGN NUMBER: 19V741000 (AIR BAGS) REPAIR, THE SERVICE TECHNICIAN INFORMED HIM THAT SEVERE CORROSION HAD FORMED ON THE TOP OF THE VEHICLE'S UNDERCARRIAGE. THE CONTACT WAS SHOWN THE CORROSION DAMAGE AND NOTICED THAT HOLES AND MISSING PARTS WERE UNDER THE SUBFRAME. THE CONTACT STATED THAT IN 2014, A SPECIAL COATING WAS PLACED ON THE UNDERCARRIAGE TO PREVENT CORROSION HOWEVER, THE COATING FAILED TO PREVENT THE RUST CONDITION. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE CONTACT WAS INFORMED THAT THE VEHICLE WAS NO LONGER UNDER WARRANTY. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS UNKNOWN.

NHTSA complaint #11386784 — an unverified report by a vehicle owner.

SUSPENSION

ORIGINAL OWNERS OF A 2004 TUNDRA DOUBLE CAB 4WD, PURCHASED NEW. WITHIN 3 YEARS, THE WHEELS BEGAN TO CORRODE. REPORT WHEEL CORROSION TO TOYOTA, THEY REPLY NOTHING THEY CAN DO. IN 2007, WITH 25K MILES, TRUCK WAS RECALLED AND HAD BALL JT REPLACED. AT 60K MILES, PARKING BRAKE MECHANISM WAS FROZEN (CORRODED) AT THE REAR WHEELS. AT APPROXIMATELY 90K MILES, FRONT SUSPENSION LEFT SIDE VERTICAL LINK FRACTURED. REPLACED LINK ON BOTH SIDES, AND RIGHT SIDE HAD DETERIORATED AND FAILURE WAS IMMINENT. WHEEL BACKING PLATES ON ALL 4 WHEELS BEGAN CORRODING. REAR BUMPER AND SUPPORT BRACKETS BEGAN TO CORRODE AT 90K MILES. NOVEMBER OF 2014, VEHICLE IS RECALLED FOR INSPECTION OF FRAME. TOYOTA DETERMINES IT DID NOT NEED REPLACING, AND SPRAY SOME TYPE OF COATING ON THE FRAME. IN OCTOBER OF 2019, AT 140K MILES, ONE OF THE TWO FUEL TANK STRAPS FAILS DUE TO CORROSION, FUEL TANK SUSPENDED BY ONE STRAP UNTIL DISCOVERED. JULY OF 2020, DISCOVER REAR AXLE DIFFERENTIAL COVER LEAKING DUE TO SEVERE CORROSION OF THE AXLE METAL. ATTEMPT TO TRADE IN VEHICLE AT TOYOTA IN OCT OF 2020, AND THEY PROVIDE A VALUE LESS THAN BOOK VALUE DUE TO CORROSION, AND STATE THEY ARE TAKING A RISK AS THE VEHICLE MAY NOT PASS INSPECTION. CALL TOYOTA CUSTOMER SERVICE TO ASK FOR ASSISTANCE OR DISCOUNT TO PURCHASE A NEW TRUCK, AS WE HAD NO INTENTION OF SELLING THE TRUCK WE HAVE CARED FOR FOR 16 YRS, WITH ONLY 150K MILES, AND NOW WITH A BAD AXLE MUST BUY ANOTHER TRUCK ASAP IN 2020. THE TRUCK WAS NOT A DAILY DRIVER, WAS NOT DRIVEN FOR A WORK COMMUTE. IT IS AN EXTRA VEHICLE, OUR "NEW" DEPENDABLE VEHICLE FOR FAMILY TRIPS, VACATIONS, COLLEGE, ETC.., AND THE CONDITION AND CARE IS OBVIOUS IN THE PHOTOS. I WOULD NOT EXPECT TOYOTA TO BUY BACK THE VEHICLE, BUT SOME ASSISTANCE COULD BE PROVIDED TO THE OWNERS FORCED TO PURCHASE ANOTHER TRUCK PREMATURELY. OUR TRUCK NEVER TRAILERED OR LAUNCHED A BOAT. RARELY DRIVEN IN SNOW.

NHTSA complaint #11364889 — an unverified report by a vehicle owner.

SUSPENSION

STARTED HEARING CLUNKING NOISE IN TRUCK. MADE APPOINTMENT WITH ASE CERTIFIED MECHANIC AND HE ASKED US TO COME BACK TO THE SHOP. THE STRUCTURE OF THE FRAME THAT HOLDS THE RACK AND PINION STEERING AND ANTI-SWAY BAR MOUNT WAS GONE. BOTH OF THE TOPS OF THE FRAME OF THE CROSS MEMBER THAT GOES UNDER THE ENGINE WAS MISSING. THE FRAME RAIL UNDER THE CAB IS SEPARATING. HE ADVISED THAT THIS CONDITION WAS A MASSIVE SAFETY ISSUE AND THAT I SHOULD CONTACT TOYOTA AND ADVISE THEM. I CALLED A DEALERSHIP IN ZANESVILLE AND THEY ADVISED THEY COULD NOT HELP BECAUSE IT WAS NOT A RECALL AND TOYOTA GAVE ME A CASE NUMBER AND TRANSFERRED ME TO SOMEONE ELSE WHO TOLD ME THEY COULD NOT HELP ME. HE ALSO GOT A SECOND OPINION FROM ANOTHER INDIVIDUAL WHO ALSO SAID THAT THIS IS A SAFETY ISSUE THAT SHOULD BE ADDRESSED BY THE MANUFACTURER. I HAVE MORE PHOTOS AND I NOW KNOW I CAN NOT DRIVE A TRUCK THAT I SPENT $24,000 ON JUNE OF 2019. I AM GLAD I DID NOT WRECK MY VEHICLE AND HURT MY FAMILY OR ANYONE ELSE BECAUSE OF THIS ISSUE. PLEASE HELP ME REPAIR MY TRUCK. WHEN WE PURCHASED THE VEHICLE THE FACTORY UNDERCOATING WAS STILL IN TACT AND THIS WAS NOT VISIBLE UNDERNEATH.

NHTSA complaint #11363645 — an unverified report by a vehicle owner.

SUSPENSION

OUR TUNDRA HAD A FRAME RECALL AND IT WAS THE DEALERS DECISION ON WHETHER OR NOT TO REPLACE DRAM OR JUST COVER UP WITH UNDERCOATING. WE DISAGREED WITH THE DECISION TO UNDERCOAT AS THE DEAL WAS SHOWING SIGNS OF EXTENSIVE RUST. NOW, OUR FRAME IS EXTREMELY DANGEROUS TO THE POINT OF FALLING AWAY FROM THE BODY. JUST ABOUT ALL PARTS UNDER THE TRUCK HAVE NOW SUFFERED AS WELL. WE HAVE NEVER HAD THE TRUCK LAUNCH A BOAT, GONE OFF ROAD, OR ANY OTHER DANGEROUS ACTIVITIES. BASICALLY A TRAIN STATION AND DUMP RUN VEHICLE. I AM TERRIBLY DISAPPOINTED WITH TOYOTA AND THEIR POOR HANDLING OF THE SITUATION. BASICALLY THEY TOLD ME THAT I WOULD BE RESPONSIBLE FOR THE SUPER EXPENSIVE FRAME REPLACEMENT; TOO BAD. ENGINE, BODY, AND INTERIOR ARE IN GREAT SHAPE. I NEED HELP AS I 1) CANNOT AFFORD TO PAY FOR THEIR MISTAKE AND 2) CAN'T AFFORD TO REPLACE THIS TRUCK AND IT IS VITAL FOR US. JUST FOUND OUT TODAY THAT THE FRAME IS DISINTEGRATING QUICKLY WHEN WE BROUGHT CAR TO SHOP FOR A STEERING ISSUE WHICH WE NOW FIND OUT WAS CAUSED BY EXCESSIVE RUST. THANK YOU

NHTSA complaint #11350418 — an unverified report by a vehicle owner.

SUSPENSION

THE FRAME OF THE VEHICLE IS SEVERELY RUSTED WITH LARGE HOLES PRESENT. THIS VEHICLE IS UNSAFE TO DRIVE AS IT PUTS MYSELF AND OTHERS IN GRAVE DANGER. TOYOTA HAS TO FIX THIS PROBLEM OR DEATHS ARE A POTENTIAL.

NHTSA complaint #11328993 — an unverified report by a vehicle owner.

SUSPENSION

SEVERE FRAME ROT. RUST HAS EATEN A HOLE THROUGH THE FRAME. HAS BEEN DEEMED UNSAFE TO DRIVE. HAS FAILED A FRAME CHECK BY ATLEAST ONE TOYOTA DEALERSHIP.

NHTSA complaint #11322188 — an unverified report by a vehicle owner.

SUSPENSION

MY VEHICLE HAS MAJOR FRAME DAMAGE. THERE ARE LARGE HOLES NEAR THE FRONT CROSSMEMBERS ON BOTH SIDES. I WAS TOLD BY TOYOTA THAT THE FRAME HAD BEEN SPRAYED SEVERAL YEARS EARLIER. HOWEVER, THE FRAME HAS CONTINUED TO RUST SEVERELY AND THE COATING HAS COMPLETELY FLAKED OFF. THE REPRESENTATIVE I SPOKE TO STATED THAT WAS THE ONLY RESOLUTION, AND THAT NOTHING CAN BE DONE. MY CASE IS NOT THE ONLY ONE. EVEN THE DEALER LOCATED NEAR ME STATES THAT THIS IS A WELL KNOWN ISSUE. SEVERAL YEARS RECEIVED NEW OR REPAIRED FRAMES FOR THE SAME ISSUE. HOW CAN IT BE, THAT THE SAME GENERATION VEHICLE ONE YEAR LATER IS NOT ELIGIBLE? MY CHILD RODE COUNTLESS TIMES IN THAT VEHICLE. WHAT IF SOMETHING HAD HAPPENED?

NHTSA complaint #11321300 — an unverified report by a vehicle owner.

SUSPENSION

ALL MY FRONT SUSPENSION COMPONENTS FAILED. I NOTICED THAT THE FRAME HAD RUSTED THROUGH NEAR THE FRONT WHEEL PASSENGER SIDE AND HAS BUCKLED AND SHIFTED AS A RESULT. MY UPPER AND LOWER BALL JOINTS AND CV AXLE WERE DAMAGED WHILE MY TRUCK WAS IN MOTION TURNING INTO THE SAFEWAY GAS STATION CHESTER MD. FEBRUARY 9 OF THIS YEAR WHEN THE SUSPENSION FAILED TO SUPPORT THE TRUCK. THE PASSENGER SIDE BALL JOINT AND CV AXLE WERE DAMAGED. TIE RODS AND SWAY BAR STABILIZERS WERE ALL WORN AND BROKEN AS WELL.

NHTSA complaint #11320907 — an unverified report by a vehicle owner.

SUSPENSION

TL* THE CONTACT OWNS A 2004 TOYOTA TUNDRA. WHILE THE CONTACT WAS INSPECTING THE REAR SUSPENSION OF THE VEHICLE, HE NOTICED THAT THE SUBFRAME, SUSPENSION SUPPORT, AND SPARE TIRE ENCLOSURE WERE EXTREMELY CORRODED. THE CONTACT ALSO STATED THAT THE SPARE TIRE HAD SEPARATED FROM THE VEHICLE. THE CONTACT WAS UNAWARE AS TO WHEN THE SPARE TIRE DETACHED. THE CONTACT STATED THAT THE VEHICLE WAS INSPECTED IN 2015 AT MCCARTHY TOYOTA OF SEDALIA (3110 W BROADWAY BLVD, SEDALIA, MO 65301, (660) 826-5400) PER A MANUFACTURER COMMUNICATIONS REGARDING FRAME RUST. AT THAT TIME, THE VEHICLE DID NOT HAVE EXCESSIVE CORROSION. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS INFORMED OF THE FAILURE. THE DEALER WAS NOT NOTIFIED. THE APPROXIMATE FAILURE MILEAGE WAS 150,000.

NHTSA complaint #11267237 — an unverified report by a vehicle owner.

SUSPENSION

PURCHASED VEHICLE FROM PRIVATE PARTY. PREVIOUS OWNER INFORMED US OF FRAME RECALL PREFORMED ON VEHICLE 3/2014 STATING TOYOTA SPRAYED FRAME WITH RUST INHIBITOR, HE COMPLAINED THAT HE WASN'T SATISFIED WITH THE RESULTS. FRAME IS NOW UNSAFE. REINSPECTED BY TOYOTA 8/2019, FRAME IS UNSAFE BUT THE RECALL HAS ENDED. VEHICLE HAS 133,000 MILES AND IS USELESS. TOYOTA PUT A BANDAID ON THE ISSUE AND CALLED IT FIXED.

NHTSA complaint #11256375 — an unverified report by a vehicle owner.

SUSPENSION

EXCESSIVE RUST ON SUB-FRAME OF VEHICLE; FRONTAL SUB-FRAME COMPLETELY RUSTED OUT ON VEHICLE WITH NO APPARENT BODY RUST; GARAGED THROUGHOUT ITS HISTORY; AND WITH LESS THAN 100K MILES; REAR FRAME RUSTED

NHTSA complaint #11195634 — an unverified report by a vehicle owner.

SUSPENSION

FRAME RUSTED THROUGH AND DANGEROUS TO OPERATE

NHTSA complaint #11182433 — an unverified report by a vehicle owner.

SUSPENSION

REAR END FAILURE DUE TO RUST PROBLEM KNOWN TO TOYOTA. THEY REPLACED FRAME WITH NO CONSIDERATION FOR SAFETY OF PASSENGERS. DRIVE TRAIN LOCKED UP WHILE DRIVING DOWN HIGHWAY. FOUND BELL HOUSING ON REAR END RUSTED THROUGH ALLOWING FLUID TO RUN OUT! DANGEROUS. TOYOTA SHOULD TAKE RESPONSIBILITY FOR BAD PRODUCT! WELDED BELL HOUSING, CANNOT REPAIR. PLEASE HELP!!!! ALMOST CAUSED WRECK! CARS SWERVED TO AVOID COLISION.

NHTSA complaint #11173552 — an unverified report by a vehicle owner.

SUSPENSION

MY FRONT ( PASSENGER ) RIGHT WHEEL ASSEMBLY RUSTED AWAY FROM FRAME.

NHTSA complaint #11047058 — an unverified report by a vehicle owner.

SUSPENSION

MY FRAME HAS RUSTED TO THE POINT IT BROKE,I BELIEVE IT FALLS UNDER THE 1ST GENERATION FRAME AS THE 2003 MODELS.I WENT FOR AN INSPECTION AND IT FAILED DUE TO FRAME

NHTSA complaint #11024948 — an unverified report by a vehicle owner.

SUSPENSION

FRAME RUSTED, CRACK AND HOLES ARE LARGER THAN 7/16 INCH THROUGH RIGHT FRONT INSIDE BEHIND MOTOR MOUNT. VEHICLE IS STATIONARY, PARKED AFTER TOYOTA EMPLOYEE VERBALLY STATED UNSAFE FOR ROAD TRIP BUT COULD BE USED AROUND TOWN. 11/11/17 SPARKS TOYOTA FRAME RECALL, CORROSION RESISTANT COMPOUND APPLIED BY BRISTOL TOYOTA ON 11/2014, AFTER BRINGING IT IN FOR RECALL OF FRAME REPLACEMENT. CONTACTED TOYOTA CORPORATE 9/20/2017 AND THEY STATED THEY COULD DO NOTHING FOR ME, CONTACT NHTSA FOR SAFETY ISSUES.

NHTSA complaint #11024676 — an unverified report by a vehicle owner.

SUSPENSION

I GOT A RECALL NOTICE ON MY VEHICLE A FEW MONTHS BACK ABOUT AIRBAGS SO I LOOKED IT UP ON THIS SITE AND IT SAYS I HAVE NO RECALLS ON MY VEHICLE THE AIRBAG LIGHT HAS BEEN ON SINCE I'VE GOT THE TRUCK BUT I THOUGHT IT WAS A ELECTRICAL ISSUE BUT NOW AFTER RECEIVING THE RECALL NOTICE AND READING THE RECALL IT REALLY HAS ME WORRIED FOR THE SAFETY OF ME MY WIFE AND MY CHILDREN I WOULD REALLY LIKE SOME INFORMATION ON THE AIRBAG RECALL AND THE SUSPENSION RECALL MY VEHICLE HAS A LOT OF THE SAME ISSUES AS THE RECALL POINTS OUT

NHTSA complaint #11021377 — an unverified report by a vehicle owner.

SUSPENSION

FRAME OF THE TRUCK IS COMPLETELY RUSTED. THE UPPER ARM BOLTS ARE NOT ABLE TO BE CONNECTED TO THE FRAME AS THE FRAME IS COMPLETELY RUSTED. THE REST OF THE FRAME IS BEING EVALUATED AT THIS TIME. CALLED TOYOTA AND THEY SAY THAT THE THIS TRUCK IS NOT PART OF THE RE-CALL, BUT THEY WILL NOT DO ANYTHING UNTIL THE NATIONAL HIGHWAY TRANSPORTATION TELLS THEM THEY HAVE TO DO EXTEND THE RECALL INTO OTHER YEARS OF THE TUNDRAS. AS OF RIGHT NOW IT ONLY INCLUDES THE 2007-2008 TRUCKS.

NHTSA complaint #11014139 — an unverified report by a vehicle owner.