2004 Toyota Tundra SUSPENSION,STRUCTURE

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.

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 This is a known issue with this model year, but Toyota says the recall is no longer valid.

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.

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.

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.

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.

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.

TL* THE CONTACT OWNS A 2004 TOYOTA TUNDRA. THE CONTACT TOOK THE VEHICLE TO CREEK SIDE AUTO MECHANIC SHOP FOR INSPECTION WHERE THE TECHNICIAN FOUND SEVERE CORROSION. TOYOTA OF GRAND RAPIDS WAS CONTACTED AND REFERRED THE CONTACT TO TOYOTA USA. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 90,000. UPDATED 08/29/17*LJ *CN

FRONT SUSPENSION STABILIZER BAR RUSTED OFF OF FRAME, RESULTING IN LARGE, STRUCTURALLY COMPROMISING HOLE IN THE WELDING LOCATION ON THE FRAME. WHEN TURNING INTO MY DRIVEWAY I HEARD THE STABILIZER BAR DETACH FROM THE FRAME. THE DRIVEWAY IS MODESTLY SLOPED WHICH CAUSED MY LEFT WHEEL SUSPENSION TO FLEX AS IT WOULD IN ANY ORDINARY DRIVING CONDITIONS. UPON INSPECTION OF THE FRAME, I NOTICED THAT THE DETACHMENT RESULTED IN A SMALL HOLE. UPON CLEANING UP THE EFFECTED AREA, HOWEVER, I NOTICED A MASSIVE HOLE IN THE FRAME. LITTLE DID I REALIZE THAT I HAD BEEN DRIVING ON A COMPLETELY UNSAFE VEHICLE THIS WHOLE TIME. TOYOTA HAS A RECALL IN PLACE FOR THESE EXACT SAME COMPONENTS FOR 2000 -2003 TOYOTA TUNDRAS. WHY ISN'T THERE A RECALL IN PLACE FOR THESE? THEY ARE THE SAME PARTS. THE FIRST TWO PHOTOS ARE BEFORE WIRE BRUSHING THE AREA. THE LAST TWO ARE FROM AFTER BRUSHING THEM. *TR

NOTICED LAST WEEK THE FRAME OF MY TRUCK WAS ROTTING ON MY DRIVEWAY! UPON FURTHER INSPECTION I DISCOVER LARGE HOLES COMPLETELY THROUGH MY BOX FRAME. AFTER CLEANING OUT ALMOST 5LBS OF ROTTED FRAME I CAN NO LONGER PUT MY FAMILY AND FRIENDS IN THIS VEHICLE. THAT WOULD MAKE ME IRRESPONSIBLE AND NEGLIGENT LIKE THE MANUFACTURER! I PURCHASED THIS VEHICLE IN JAN 2015 WHEN IT ONLY APPEARED TO BE A SURFACE RUST ISSUE. RECIEVED NOTICE OF THE LIMITED SERVICE CAMPAIGN THE MONTH AFTER IT WAS OVER SO TOYOTA REFUSED TO EVEN INSPECT IT. NOW THIS YEAR I HAVE HOLES YOU CAN PUT YOUR HAND THROUGH AND TOYOTA STILL REFUSES THE FRAME IS BAD. IN THE LIMITED SERVICE CAMPAIGN TOYOTA SAYS "THE CONDITION IS UNRELATED TO AND SEPARATE FROM NORMAL SURFACE RUST". HOW COULD THIS BE S VOLUNTARY LIMITED SERVICE CAMPAIGN AND NOT A MANDATORY SAFETY RECALL?? SOUNDS LIKE A LOOPHOLE CREATED BY DESIGN!

TL* THE CONTACT OWNS A 2004 TOYOTA TUNDRA. THE CONTACT STATED THAT THERE WAS AN ABNORMAL NOISE COMING FROM THE VEHICLE. IT WAS TAKEN TO A DEALER FOR A FRONT END ALIGNMENT AND THE MECHANIC INDICATED THAT THE SWAY BAR FRACTURED FROM THE FRAME. IN ADDITION, THE MECHANIC STATED THAT THERE WAS EXTENSIVE RUST ON THE SWAY BAR AND FRAME. THE DEALER INDICATED THAT THE SWAY BAR AND THE FRAME NEEDED TO BE REPLACED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE AND INDICATED THAT THERE WAS NO RECALL TO ADDRESS THE REPAIR. THE FAILURE MILEAGE WAS NOT AVAILABLE.

TL*THE CONTACT OWNS A 2004 TOYOTA TUNDRA. THE CONTACT STATED THAT THE VEHICLE WAS SEVERELY CORRODED AND AFFECTED THE POWER TRAIN, REAR END, WHEEL, AXLE AND BELT HOUSING. THE CONTACT RECEIVED A NOTICE FOR NHTSA CAMPAIGN NUMBER: PE09049 (FUEL SYSTEM, GASOLINE , SERVICE BRAKES, HYDRAULIC , STRUCTURE , TIRES) AND THE DEALER WAS MADE AWARE OF THE FAILURE. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 86,000.

AFTER A SCHEDULED OIL CHANGE THE MECHANIC SUGGESTED I TAKE MY TRUCK TO A TOYOTA DEALER TO CHECK OUT THE UNDERCARRIAGE RUST. WHEN TO MASSEY TOYOTA, WHITE OAK, PA . THEY SAID I NEED TO DEAL WITH IT BUT IT WOULD COST SEVERAL HUNDREDS OF DOLLARS BECAUSE TOYOTA DOESN'T HAVE A RECALL ON 2004. I'VE TALKED TO OTHER TUNDRA OWNER WITH THE SAME PROBLEMS. WHEN IS TOYOTA GOING TO ACKNOWLEDGE THIS MANUFACTURING PROBLEM AS YOU DID PREVIOUS MODELS? I CURRENTLY OWN TWO TOYOTA'S: TUNDRA AND CAMRY. *TR

MAIN FRAME SUPPORT FRONT OF VEHICLE ; WHOLES HAVE RUSTED THROUGH. SUPPORTS ENGINE! *TR

FRAME ROTTED THROUGH. DEALER STATED( APPROX) 75 PERCENT OF FRAME WHERE SWAYBAR WAS WELDED TO FRAME IS GONE..SWAYBAR IS ROTTED OFF PASSENGER SIDE FRAME. ADVISED NOT TO DRIVE ANYMORE. TOOK TO DEALER AS REQUESTED BY TOYOTA MOTOR CORPORATION. THEY TOOK PICTURES AND SENT THEM TO TOYOTA REPRESENTATIVE. *TR

BROUGHT MY TRUCK IN FOR AN OIL CHANGE. I WAS CALLED AT WORK BY MY GARAGE, THEY TOLD ME THE TRUCK WAS UNSAFE TO DRIVE DUE TO SEVERAL HOLES AND CRACKS IN THE FRAME DUE TO SEVERE RUST. I BROUGHT THE TRUCK TO THE DEALER I PURCHASED IT FROM AND THEY AGREED THAT THE TRUCK WAS NOT DRIVABLE. TOYOTA HAS SAID THE 04 MODEL IS NOT PART OF THE RECALL, AND I APPEAR TO BE IN LIMBO. IT HAS BEEN 3 WEEKS AND THIS ISSUE IS STILL UNRESOLVED. THE ONLY CERTAINTY IS THAT THE TRUCK WILL NEED MANY NEW FRAME COMPONENTS FOR IT TO BE ROAD WORTHY AGAIN. *TR

I TOOK MY TRUCK TO THE TOYOTA DEALER BECAUSE OF A NOISE IN THE FRONT END. IT TURNS OUT THE FRAME AT THE ATTACHMENT POINTS FOR THE STABILIZATION BAR WAS BADLY RUSTED. THERE ARE RUST HOLES IN THE FRAME AND THE ATTACHMENT POINT ON THE LEFT SIDE HAD RUSTED FREE OF THE FRAME AND THE OTHER SIDE IS NOT TO FAR BEHIND. TOYOTA HAS A HISTORY OF RUSTED FRAMES BUT ACCORDING TO THE VIN NUMBER IT IS NOT PART OF THE CURRENT RECALLS. I WAS TOLD SORRY WE CAN'T FIX IT. THIS IS NOT RIGHT!!!! CAN YOU HELP. *TR

FRAME IS BADLY RUSTED IN MANY AREAS INCLUDING WHERE SUSPENSION AND BRAKE COMPONENTS MOUNT. I AM CONCERNED A MAJOR FAILURE COULD LEAD TO INJURY TO MYSELF OR A MEMBER OF MY FAMILY. I UNDERSTAND THERE WAS A RECALL FOR 2000-2003 TUNDRAS FOR THE SAME ISSUE BUT MY 2004 WAS NOT INCLUDED IN THE RECALL. *TR

2004 TOYOTA TUNDRA TAKEN IN FOR SERVICE ON 05/18/13. WELL CARED FOR VEHICLE AND SERVICED FAITHFULLY AT EVERY INTERVAL.TOLD BY SERVICE MANAGER THAT THE FRAME HAS A HOLE IN IT.THIS IS A KNOWN PROBLEM BY TOYOTA. FRAME IS VERY RUSTY AND WAS PART OF A PROBLEM TOYOTA HAD WITH A BAD BATCH OF METAL USED FOR FRAMES.SERVICE MANAGER COULD OFFER NO RELIEF FOR THIS PROBLEM AND REFERRED ME TO TOYOTA CUSTOMER CARE. CUSTOMER CARE COMPLAINT NUMBER [XXX]. CUSTOMER CARE ADVISED THEY COULD DO NOTHING ABOUT THIS AND BASICALLY HAVE A NICE DAY. SERVICE MANAGER ADVISED THAT I SHOULD BE CAREFUL WHEN GOING OVER BUMPS. WHAT SHOULD BE A 14 TO 16 THOUSAND DOLLAR VEHICLE IS NOW WORTH NOTHING. SHAME ON TOYOTA FOR SELLING FAULTY AND UNSAFE EQUIPMENT. ACCIDENT WAITING TO HAPPEN. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

AT THE SERVICE CENTER I WAS ADVISED THAT MY TRUCK HAD EXTENSIVE FRAME RUST. I CONTACT LOCAL TOYOTA DEALERSHIP (WAPPINGERS DCH) AND SERVICE MANAGER SAID IT IS KNOW PROBLEM WITH THIS GENERATION TUNDRA. TOYOTA CURRENTLY BUYING BACK 2000-2003, BUT MY 2004 WAS NOT YET INCLUDED. HE ADVISED THAT I WAIT TO HEAR BACK. CONTACT TOYOTA AND WAS TOLD MAYBE, BUT I NEEDED TO WAIT. I WAS ALSO TOLD THAT THERE WAS AN INSPECTION RECALL AND FRAME REPAIR OPTION FOR THIS, BUT THEY DID NOT HAVE ME ON FILE AS OWNER, SO I WAS NOT CONTACTED. I HAVE OWNED THIS TRUCK FOR 4 YEARS AND SERVICED IT AT A REGISTERED TOYOTA DEALER. THEY WERE NOT ABLE TO ANSWER WHAT HAPPENED AND RECOMMENDED THAT I WAIT. NOW I CAN'T PASS INSPECTION OR DRIVE MY TRUCK AND I'M STUCK. PLEASE ADVISE. *TR

EXCESSIVE RUST ACCUMULATION ON FRAME OF TRUCK. RECALL CAMPAIGN # 09V444000 STATES TOYOTA WILL INITIATE A FIELD ACTION ON 2004 THROUGH 2006 MODELS. CALL TO TOYOTA CUSTOMER RELATIONS (CASE # [XXX]), PROVED TO BE USELESS. NO ACTION BEING TAKEN BY TOYOTA. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

MY 2004 TOYOTA TUNDRA LIMITED, PURCHASED IN 2004 DIRECTLY FROM TOYOTA DEALERSHIP FOR 39000 DOLLARS HAS AN EXTREMELY RUSTY FRAME. THE STEEL PEELS AWAY IN LAYERS AT THE WELDS. THE PROLIFERATION CAN BE DESCRIBED AS "LAYERS OF A BISCUIT FLAKING A PART." THE DEALERSHIP POUNDED ON THE FRAME WITH A TOOL AND SAID THAT IT DID NOT FAIL THE "TOYOTA FRAME TOOL" TEST AND SINCE THE VEHICLE IS A 2004 THEY WOULD NOT DO ANYTHING ABOUT IT UNTIL IT FAILS OR BECOMES PART OF A RECALL. I HAUL A TRAVEL TRAILER WITH MY FAMILY AND I FEEL THAT IT IS EXTREMELY UNSAFE. HOW CAN A 7.8 YEAR OLD TRUCK ROT OUT THIS QUICKLY? THERE HAS A TO BE AN ISSUE HERE THAT TOYOTA IS NOT WILLING TO ACKNOWLEDGE. PLEASE ADVISE. *TR