2003 Toyota Tundra Structure

There was a recall for the frame rusting out prematurely. Toyota had the recall until 2012. I did not own the truck then and it did not get fixed. Now I have a rusted out frame. Toyota is claiming they are not able to fix the frame due to it being 14 years later. They would however be able to keep the recall open if it is a safety recall. I don't know how a rusted out frame wouldn't be anything other than safety. The truck has less than 80,000 miles. What automobile should have a rusted out frame with less than 100,000 miles?!

The frame is bad on driver and passenger side between the cab and bed. Auto body tech states there is no good metal to make the necessary repairs (welding new metal) to at this time. Inspection garage states it is a solid truck but will not pass inspection due to the frame’s condition. The vehicle has 106k miles on it with one surface area of rust. The vehicle has been well maintained and is mechanically in good condition. Toyota should have replaced the frames because they knew there was an issue. Can NHTSA help with a resolution?

The contact owns a 2003 Toyota Tundra. The contact stated while in the process of selling the vehicle, the potential buyer inspected the subframe and informed the contact that the frame was severely rusted inside and outside. The vehicle was taken to an independent mechanic, where it was inspected. The mechanic confirmed the failure and informed the contact that the six bolts holding the bed securely were severely rusted. The contact was provided an estimate for a partial external repair of the subframe. The vehicle was not repaired. The contact stated that the dealer had previously sprayed a corrosion protective compound on the vehicle under NHTSA Campaign Number: 09V444000 (Structure); however, the failure progressively worsened. The dealer and the manufacturer were notified of the failure. The vehicle was not repaired. The failure mileage was approximately 119,000.

The 2003 Toyota Tundra is known for severe frame rot due to improper rust protection, which led to a major safety recall. The excessive corrosion can cause rust holes to form in the frame, compromising the vehicle’s structural integrity. This can lead to frame cracking or even complete failure, making the truck extremely dangerous to drive. A weakened frame affects the vehicle’s ability to absorb impact in a crash, reduces stability, and can lead to suspension or steering failure. In extreme cases, parts like the fuel tank or spare tire can detach, increasing the risk of a serious accident.

The contact owns a 2003 Toyota Tundra. The contact stated while working underneath the vehicle, he became aware that the junction point on the frame rail of the front driver’s side was rusted. The vehicle was taken to the dealer where the rust was confirmed and pictures and documentation that the frame needed to be replaced were submitted to Toyota Chicago regional however, the subframe replacement was denied by the dealer. The manufacturer was contacted who informed the contact to find another 2003 Toyota Tundra owner where they had remedied the frame rust failure free of charge. The contact stated that the other vehicle owner informed him that Toyota offered to replace the frame or buy back the vehicle. The contact stated he provided the information to Toyota with the other owner's information and VIN, however, the contact stated that Toyota had not offered to replace the frame or buy back the vehicle. The contact stated that the vehicle was serviced in 2013 under NHTSA Campaign Number: 09V444000 (Structure) at Toyota West (1500 Auto Mall Dr, Columbus, OH 43228) however, the rust failure occurred. The contact stated that the remedy was insufficient. The contact stated that a case was opened. The approximate failure mileage was 200,000.

In October 2024, my truck's frame exhibited significant rust, a defect that aligns precisely with a previous recall on this model. The rust has spread to critical parts, making the vehicle unsafe to drive. This directly threatens the safety of my son, who relies on this truck for transportation. The rust compromises the frame's integrity, risking structural failure and potential loss of vehicle control. This defect was not previously flagged by warning lamps or messages and was only recently discovered through visual inspection. This issue has been documented in the past and is consistent with a recall initiated a year ago. This recall specifically cited frame rust as a critical defect, and my vehicle is one of those affected models. Given the safety concerns, the severity of frame rust, and the recall history, the frame needs immediate replacement. This action is crucial to ensure my son's safety and prevent potentially life-threatening incidents on the road.

On 4/19/2024 I arrived for an appointment at Corwin Toyota of Bellvue, Nebraska for inspection of my vehicles known recall of the frame due to excessive rust and potential failure due to a faulty manufacturing process. My vehicle is a 2003 Toyota Tundra SR5, Access Cab. Upon arrival, the service representative, and later corroborated by his manager, refused to inspect my vehicle stating "work had already been done on my frame". That is not true. I am the original owner of said vehicle and had it inspected in approximately 2010 after being informed of the recall, likely at a dealership in Denver Colorado where i was residing at the time. At that time was informed vehicle frame did not have excessive rust and NO work was done. The vehicle was purchased in Colorado Springs from Corwin Toyota (same dealership franchise company?), in 2003. Since then, the vehicle has lived in Nebraska and Iowa for most of its existence where salt is used on roads extensively in the winter. I was informed by the service representative at the dealership they will not look at it as they show it has already had repairs done to the frame as I stated. This is false. No work has been done on my vehicles frame at any point and is now experiencing significant frame rust. At some point, maybe at inspection in 2010, maybe later, that some work had been done making the frame ineligible for future inspection or repair or replacement. I am sure Toyota and its agents, Toyota dealerships, are highly motivated to exclude as many vehicles associated with this frame recall as possible. I am certain I am not the only one experiencing this fraud on the consumer. Please investigate whom allegedly did work on my frame, when, and what specifically. I expect the ability to have my frame legitimately inspected and actual repairs or replacement of effected part(s) as resolution. I will be contacting the manufacturer but expect the same run around without your direct involvement. Thank you in advance.

The contact owns a 2003 Toyota Tundra. The contact stated that an unknown recall for structure corrosion was completed on the vehicle in February 2012 at a local dealer. The contact stated on June 2022, he noticed that the subframe was corroded. The vehicle was taken to an independent mechanic, where it was diagnosed that the subframe needed to be replaced. The local dealer was made aware of the failure. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was approximately 145,000.

Frame is rusted and unsafe to be driven. I loved this truck but now what good is it?

I have a 2003 Toyota Tacoma 2 wheel drive The frame is rotted With only a 140000 miles on itAnd the manufacturer won't help me anymore so I don't know what to do with this vehicle now.

Frame is rotten. Recently purchased truck from a private party. Did not notice frame rust at time of purchase. It is bad. Can fit more than a marble through the hole in picture. Read up on it online. Common problem. Upon going underneath truck all frame is decaying. It appears it may have previously been sealed. Which may have cracked away and trapped moisture in just making problems worse. On top of that one thread I read stated guy took his truck to dealer and they told him by law they could not let him leave due to rust issue. Mine is an 2003 Toyota Tundra sr5 access cab 2wd terminator edition. Please help. I was also able to look up on Toyota website under owners and found a shop stated not safe to drive or even lift in November of 2020. And since then truck has only had about 700 miles put on. 120 miles was from guy driving it to me to sell to me. I’m now worried if I drive this in it’s current state that at any time it could break and cause an accident.

CRAKE IN FRAME

The contact owns a 2003 Toyota Tundra. The contact stated while the vehicle was being emissions tested, he was informed that the sway bars and the rear cross members were corroded. The VIN was associated with NHTSA Campaign Number: 09V444000 (Structure). The contact took the vehicle to the local dealer and was informed that the location of the corrosion was not covered under the recall. The vehicle was not repaired. The contact took the vehicle to several independent mechanics who declined to service the vehicle due to the damage of the corrosion. The vehicle was not repaired. The manufacturer had been informed of the failure. The failure mileage was approximately 153,000.

The contact owns a 2003 Toyota Tundra. The contact stated while having the vehicle repaired under an unknown recall, he was informed that the sub frame needed to be replaced. The manufacturer was informed of the failure but offered no assistance. The failure mileage was approximately 118,485.

RECALL ID U7BS-ZTW. TOOK IN FOR AIRBAG RECALL. INSPECTION OF FRAME. FRAME NEEDS TO BE REPLACED AND DEALERSHIP WOULD NOT LET ME HAVE MY TRUCK BACK.THEY GAVE ME A INFERIOR LOANER.. TOOK TRUCK IN FIRST WEEK OF S JANUARY.AS OF 3-5-21 THEY HAVE NO REPAIR SCHEDULE EITHER!. TRUCK IS AT TOYOTA OF MUNCIE IN. ALEC BAILY IS MY SERVICE MANAGER. ABAILY@TOYOTAOFMUNCIE. WORK ORDER NUMBER NC736011 AND NCOO1101. I HAVE BEEN IN CONTACT WITH TOYOTA CUSTOMER EXPERIENCE SINCE FEBRUARY. SEVERE RUN AROUND. INCIDENT #S 210125000031, 210217000381,210304000232. NATIONAL REF#S 210250103,2103042076. IF IT CANNOT BE REPAIRED I WOULD LIKE TO KNOW

2003 Toyota Tundra. Consumer writes in regards to NHTSA safety recall related to rusted frames.

UNSAFE TO DRIVE SO MUCH CORROSION ON FRAME

THE CROSS MEMBER ON MY 2003 TOYOTA TUNDRA (PART NO. 51206) IS EXHIBITING EXTENSIVE AND PREMATURE RUST AND CORROSION AT BOTH CONNECTION POINTS WITH THE MAIN FRAME RAILS SUCH THAT THE MAIN FRAME RAILS HAVE RUSTED THROUGH, LEAVING MULTIPLE HOLES APPROXIMATELY THE SIZE OF A QUARTER. THE CROSS MEMBER SUPPORTS THE FUEL TANK, AMONG OTHER COMPONENTS, AND THUS THE CORROSION POSES A SIGNIFICANT SAFETY HAZARD. AS A RESULT, THE VEHICLE, WHICH IS OTHERWISE IN SATISFACTORY AND OPERATIONAL CONDITION, FAILED ITS ANNUAL STATE INSPECTION. TOYOTA PREVIOUSLY APPLIED A RUST INHIBITOR TO THE FRAME UNDER ITS LIMITED SERVICE CAMPAIGN WHICH WAS INTENDED TO REMEDY THE DEFECT, BUT SUCH APPLICATION FAILED TO PREVENT THE PREMATURE CORROSION AND TOYOTA HAS SINCE REFUSED TO REMEDY THE DEFECT.

TL* THE CONTACT OWNS A 2003 TOYOTA TUNDRA. THE CONTACT STATED THAT THE VEHICLE WAS TAKEN TO PRIME TOYOTA - SACO (783 PORTLAND RD, SACO, ME 04072) FOR THE FREE TAKATA AIR BAG RECALL AND WAS INFORMED THAT THE SUB-FRAME WAS EXTREMELY CORRODED. THE CONTACT WAS INFORMED THAT THE SUB-FRAME RECEIVED A RUST INHIBITOR TREATMENT IN 2010 UNDER A CUSTOMER SATISFACTION PROGRAM. THE CONTACT STATED THAT THE RUST INHIBITOR TREATMENT FAILED TO PREVENT THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE BUT OFFERED NO ASSISTANCE. THE FAILURE MILEAGE WAS APPROXIMATELY 172,000.

SHOCK ABSORBERS BROKEN FROM FRAME. PART OF FRAME BROKEN. *TR

TL* THE CONTACT OWNS A 2003 TOYOTA TUNDRA. THE CONTACT STATED THAT WHILE THE VEHICLE WAS AT AN INDEPENDENT MECHANIC FOR A ROUTINE CHECK, THE MECHANIC BECAME AWARE THAT THE SUBFRAME WAS SEVERELY CORRODED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 118,000.

MY FRAME IS ROTTEN. IT'S TOTALLY UNSAFE

I RECENTLY HAD AN EXHAUST LEAK ON MY TRUCK AND WOULD OCCASIONALLY HEAR SOME CLUNKING NOISES UNDER THE VEHICLE. I WENT UNDER THE TRUCK TO INVESTIGATE THE EXTENT OF THE EXHAUST LEAK AND NOTICED THAT ONE OF THE SWAY BAR LINKS WAS NO LONGER CONNECTED AND THAT ONE END WAS RUSTED OFF. I ORDERED REPLACEMENT PARTS AND TRIED TO JACK THE VEHICLE UP UNDER THE FRAME AND I HEARD CRUNCHING AND SAW THE JACK PRESSING INTO THE FRAME FROM THE BOTTOM AND CRUMBLES OF RUST CAME SHOWERING DOWN. I RELOCATED THE JACK TO A DIFFERENT PORTION OF THE FRAME AND CONTINUED TO JACK IT UP AND MORE CREAKING OF THE FRAME AND RUSTY PARTS BROKE FREE AND FELL TO MY DRIVEWAY. THE FRAME BEHIND THE DRIVER'S SIDE FRONT WHEEL IS BADLY RUSTED AND HAS LOST ITS STRUCTURAL INTEGRITY. THERE ARE SEVERAL 5"+ HORIZONTAL AND VERTICAL "CUTS" INTO THE FRAME BOTH ON THE SIDE AND BOTTOM SURROUNDING THE NEARBY FRONT CROSS-MEMBER. THIS EXCESSIVE RUST CORROSION COMPROMISES THE VEHICLE'S SAFETY, STABILITY, AND CRASH-WORTHINESS. WE CAN NO LONGER USE THIS TRUCK FOR ITS INTENDED PURPOSE OF HAULING A HEAVY PAYLOAD OR TOWING A TRAILER WHICH WERE ENGINEERED BY TOYOTA. THIS HAS ALSO GREATLY AFFECTED THE VALUE OF THE VEHICLE. WE TOOK THE VEHICLE TO THE TOYOTA DEALER IN WESTMINSTER, MD AND THEY PERFORMED THE ANTI-RUST SPRAY TREATMENT TO THE FRAME IN 2010 UNDER THE LIMITED SERVICE CAMPAIGN WHICH OBVIOUSLY DIDN'T WORK. THE EXTERIOR PAINTED SURFACES OF THE BODY ARE ALL IN EXCELLENT CONDITION AS I APPLIED A COATING OF WAX AT LEAST ANNUALLY. THE TRUCK HAS JUST NOW REACHED 90,000 MILES AND I DON'T FEEL THAT I GOT THE VALUE OUT OF THE TRUCK FOR WHAT I PAID BRAND NEW FOR IT BACK IN 2003 WHEN I TRUSTED THE TOYOTA NAME. I RECENTLY CONTACTED THE TOYOTA DEALER IN WESTMINSTER, MD AGAIN AND I WAS TOLD THAT THE RECALL FOR THE FRAME EXPIRED IN 2012 AND THAT THERE WAS NOTHING ELSE THEY COULD DO.

TL* THE CONTACT OWNS A 2013 TOYOTA TUNDRA. WHILE HAVING ROUTINE MAINTENANCE AT AN INDEPENDENT MECHANIC ON THE FRONT WHEEL BEARING, THE FRAME CRACKED INTO TWO PLACES BEHIND THE CAB WITHOUT WARNING. THE VEHICLE WAS UN-DRIVABLE. THE CONTACT CALLED GRAHAM TOYOTA (1515 W 4TH ST, MANSFIELD, OH 44906 (419) 529-1800) BUT WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS CONTACTED WHO PROVIDED CASE 2001 021145 HOWEVER, NO FURTHER ASSISTANCE WAS PROVIDED. THE FAILURE MILEAGE WAS APPROXIMATELY 126,000.

ON 12/05/11 NEWARK TOYOTA COMPLETED RECALL SSC90M PHASE 2-CRC APPLICATION TO MY RUSTED FRAME. ALMOST IMMEDIATELY I NOTICE A BONDING FAILURE AND DELAMINATION OF THE CRC APPLICATION. BY NOVEMBER OF 2013 I ASKED THE SAME SERVICE LANE MANAGER, BILL C. AND THE TECHNICIAN THAT PERFORMED THE WORK TO INSPECT THE FAILED APPLICATION. I ASKED THE TECHNICIAN WHY IT FAILED AND HE STATED "I DID NOT PREPARE THE SURFACE CORRECTLY BEFORE I PLACED THE APPLICATION". I APPRECIATED HIS HONESTY BUT WAS TOLD THEN THAT THERE WAS NOTHING ELSE THEY COULD DO ABOUT IT. MY FRAME IS NOW VERY RUSTED SO I ASKED BILL C. TO REINSPECT MY FRAME ON 12/5/19 WHILE MY TUNDRA WAS IN FOR A TAKATA AIRBAG RECALL. WILLIAM TOLD ME THAT HE HAD A MANAGER INSPECT MY FRAME AND THAT NO PERFORATIONS WERE FOUND (PLEASE SEE ALL ATTACHED PHOTOS). THEY DID NOT MENTION THE CATASTROPHIC FAILURE OF THE FRAME C CHANNEL LOWER FLANGES. THIS EXPONENTIALLY EXPANSIVE CORROSION HAS REACHED THE LEAF SPRING BRACKET FLANGE RIVETS (SEE PHOTO 8810); CATASTROPHIC FAILURE OF THE REAR AXLE ASSEMBLY WILL RESULT. I AM A MECHANICAL ENGINEER WITH EXTENSIVE TRAINING AND EXPERIENCE IN CORROSION RELATED FAILURE. THIS FRAME AND VEHICLE ARE UNSAFE! ON 12/21/19 I EMAILED THIS INFORMATION, INCLUDING THE PHOTOGRAPHS AND COPIES OF ALL SERVICE RECORDS, TO THE TOYOTA CUSTOMER CARE CENTER. THEY EMAILED ME BACK ON 12/28/19 AND ASKED ME TO CALL THEM. THE TOYOTA REPRESENTATIVE, JEFFERY M., CALLED MY DEALERSHIP AND TOLD ME THAT THE FRAME WAS NOT PERFORATED SO I AM NOT ELIGIBLE FOR THE FRAME REPLACEMENT RECALL. I ASKED JEFFERY MULTIPLE TIMES IF THE DEALER SAID THE FRAME IS SAFE OR NOT. HE REFUSED TO ANSWER THAT QUESTION AND WOULD ONLY STATE THAT MY FRAME IS NOT PERFORATED. THE NHTSA/TOYOTA 10MM PERFORATION CRITERIA IS INADEQUATE AND THE PHASE 2 APPLICATION BONDING FAILURE EXACERBATED MOISTURE AND ROAD SALT RETENTION.