60 complaints reported

2005 Toyota Tundra Structure

Owner-reported problems and safety issues filed with NHTSA. Review common failures, severity levels, and complaint trends over time.

Reports
60
Crashes
1
Fires
0
Injuries
0

Complaint Timeline

Chronological view of owner reports

Dec 2025

1)Frame is rusting out. Not repairable. 2) Fuel tank strap rusted through and broken.

Type: Vehicle, Vehicle: 2005 TOYOTA TUNDRA, Manufacturer: Toyota Motor Corporation
Incident: Dec 2025
Sep 2025

The frame is so rusted in my truck my mechanic said it may snap at anytime and is not safe to drive. I know Toyota tundra’s from 2000-2003 have been recalled for same reason.

Type: Vehicle, Vehicle: 2005 TOYOTA TUNDRA, Manufacturer: Toyota Motor Corporation
Incident: Sep 2025
Dec 2024

The contact owns a 2005 Toyota Tundra. The contact stated that the sub frame was rusted and had holes. The parking brake and oil warning lights were illuminated. The vehicle was taken to the local dealer, who determined that the vehicle might not pass a safety inspection due to the position of the holes and rust. The warning lights were repaired but the sub frame was not repaired. The vehicle was taken to a frame shop, the frame shop declined to service the vehicle. The manufacturer was contacted and informed the contact about an Extended Warranty, but no assistance was provided. The failure mileage was approximately 139,000.

Type: Vehicle, Vehicle: 2005 TOYOTA TUNDRA, Manufacturer: Toyota Motor Corporation
Incident: Jan 2024
Aug 2024

know issue with Toyota Tundra Frame, and refuse to give option to repair.

Type: Vehicle, Vehicle: 2005 TOYOTA TUNDRA, Manufacturer: Toyota Motor Corporation
Incident: Aug 2024
Jun 2024

We are the first owner of this 2005 Toyota Tundra Limited with only 91K miles. The frame is rusted so badly that we are afraid to drive down the road. This rusted problem could cause potential harm or death to us and others on the road.

Type: Vehicle, Vehicle: 2005 TOYOTA TUNDRA, Manufacturer: Toyota Motor Corporation
Incident: Jun 2024
Nov 2023

Severe frame rust due to cheap frame material. Earlier year models were recalled but 05 and 06 were not, just a limited campaign. Frame looks like it has been coated before, but this is a known issue with these trucks. I have contacted Toyota and they basically said, sorry, we can't do anything.

Type: Vehicle, Vehicle: 2005 TOYOTA TUNDRA, Manufacturer: Toyota Motor Corporation
Incident: Jan 2023
Oct 2023

Severe rust throughout the frame

Type: Vehicle, Vehicle: 2005 TOYOTA TUNDRA, Manufacturer: Toyota Motor Corporation
Incident: Oct 2023
Aug 2023

Original owner. Well known frame rust safety issue as documented by thousands of 2005 Tundra owners. Toyota did an inspection for frame rust several years ago and opted for coating to deal with issue hastily given the long delay/backlog with replacing entire frame. Two wrongs don’t make a right. Now major safety/inspection issues with frame area and gas tank. Unable to allow my child to drive back to college. Not safe. Not worth risking kids lives. Would be interested to learn how many owner/operators need to report serious injury/fatalities before NHTSA enforces action against Toyota for corporate greed.

Type: Vehicle, Vehicle: 2005 TOYOTA TUNDRA, Manufacturer: Toyota Motor Corporation
Incident: Jan 2023
Dec 2022

The driver's side front frame has rotted out disconnecting the mount for the anti-roll bar. This has happened despite several reports to the dealership going back many years that the frame was rusting rapidly which, upon examination, they said that it was OK. They did apply a coating which might have delayed the process a bit but ultimately resolved nothing. For trucks that had perforated frames during the first few years, they replaced the frame. I tried to take care of mine, but it has finally failed and they say the replacement program is over. They are unwilling to provide even the necessary frame section and mounting bracket for the sway bar (~$545) for the frame shop to install %(2120).This vehicle has less than 98,000 miles on it and is used for short trips performing farmette duties. Frame failure can cause catastrophic accidents and should not be ignored by the manufacturer regardless of age. They know they used bad steel and should act accordingly. My action has been delayed by storm damage to frame shop which didn't reopen until December.

Type: Vehicle, Vehicle: 2005 TOYOTA TUNDRA, Manufacturer: Toyota Motor Corporation
Incident: Aug 2022
Dec 2022

The contact owns a 2005 Toyota Tundra. The contact stated while performing a routine inspection, the contact noticed that the subframe was rusted on the front and the rear suspension of the vehicle. The vehicle was taken to the dealer and the mechanic stated that the vehicle had a spray-on coating however, the vehicle was rusted and the subframe needed to be replaced. The vehicle was not replaced. The manufacturer was not contacted. The failure mileage was 60,000.

Type: Vehicle, Vehicle: 2005 TOYOTA TUNDRA, Manufacturer: Toyota Motor Corporation
Incident: Dec 2022
Jan 2022

The contact owns a 2005 Toyota Tundra. The contact stated that he was informed at the State Inspection facility that the entire sub-frame of the vehicle was severely corroded. The dealer was not notified of the failure. The manufacturer was notified of the failure and advised the contact that they could not assist as the vehicle was not included in a recall related to the failure. The vehicle was not diagnosed or repaired. The failure mileage was approximately 148,518.

Type: Vehicle, Vehicle: 2005 TOYOTA TUNDRA, Manufacturer: Toyota Motor Corporation
Incident: Jan 2022
Dec 2021

The contact owns a 2005 Toyota Tundra. The contact stated that he was made aware of the vehicle's frame corrosion by an independent mechanic. The dealer was made aware of the failure but informed the contact that there was no recall associated with the VIN. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 98,000.

Type: Vehicle, Vehicle: 2005 TOYOTA TUNDRA, Manufacturer: Toyota Motor Corporation
Incident: Dec 2021
Oct 2021

This vehicle was purchased as a certified used vehicle from Johnston Toyota. It was recalled by Toyota for a rust problem. In October 2014 the vehicle was treated by the dealer (Johnston Toyota) with a rust inhibiting compound due to the rust problem. Approximately 1-2 years ago this vehicle was inspected by an independent mechanic who stated that the vehicle was badly rusted, and he believed that Toyota had a program to address this issue. I spoke to the Toyota service department and I was told that this vehicle is not covered. Approximately 2 weeks ago an independent mechanic advised the rust problem is extensive and the vehicle will be unsafe to operate. Although Toyota advises that this is a widespread problem for this type vehicle, they refuse to address it. Furthermore, when I asked them why the rust inhibiting compound they used to correct the problem did not solve the issue, they further refuse to respond.

Type: Vehicle, Vehicle: 2005 TOYOTA TUNDRA, Manufacturer: Toyota Motor Corporation
Incident: Jan 2021
Sep 2021

The contact owns a 2005 Toyota Tundra. The contact stated that while the vehicle was in for the state inspection, it was discovered that the subframe had sustained severe rusting and corrosion causing the vehicle to fail the state inspection. The cause of the rusting and corrosion was not determined. The local dealer and manufacturer were notified of the failure. The contact indicated that the vehicle was previously treated with a rust inhibitor coating, but the failure still occurred. The failure mileage was 311,000.

Type: Vehicle, Vehicle: 2005 TOYOTA TUNDRA, Manufacturer: Toyota Motor Corporation
Incident: Nov 2021
Jul 2021

Frame is rusted. Whole on front passenger side frame.

Type: Vehicle, Vehicle: 2005 TOYOTA TUNDRA, Manufacturer: Toyota Motor Corporation
Incident: Dec 2021
Jul 2021

FRAME IS VERY RUSTY. STRAP HOLDING FUEL TANK IS DANGEROUS , REAR SUSPENTION ,AND SHOCKS BROKEN

Type: Vehicle, Vehicle: 2005 TOYOTA TUNDRA, Manufacturer: Toyota Motor Corporation
Incident: Jul 2021
Jun 2021

I PURCHASED A 2005 TOYOTA TUNDRA UNAWARE OF THE WIDE-SPREAD RUST ISSUES THIS MODEL FROM TOYOTA IS SUFFERING. THE VEHICLE CAME WITH AN INSPECTION STICKER FROM THE DEALER SO IT WAS WELL PAST THE DEALER'S WARRANTY WINDOW TO DO ANYTHING ABOUT THIS ONCE I FOUND OUT ABOUT THE ISSUE. THE VEHICLE WAS PURCHASED IN MAINE AND WAS SOLD TO ME IN NEW YORK. I WAS INFORMED BY MY MECHANIC THAT THERE ARE 4 SERIOUS RUST ISSUES PRESENT ON THE VEHICLE THAT PREVENT IT FROM PASSING INSPECTION. 1) A LARGE SEVERAL SQUARE INCH PERFORATION IN THE CENTER OF THE FRAME MEMBER 2) "PANCAKING" PRESENT ON A LARGE SECTION OF THE FRAME 3) A LARGE PERFORATION IN ONE OF THE FRAME'S CROSS MEMBERS 4) A SIGNIFICANTLY RUSTED BODY MOUNT SOMEHOW, ONLY MODEL YEARS 2000-2003 WERE RECALLED FOR THE TUNDRA BY TOYOTA, AS IF THE REST OF THE GEN 1 TUNDRAS DIDN'T HAVE THE EXACT SAME FRAME PART NUMBER. WORSE YET, I REGISTERED ON TOYOTA.COM AND FOUND THAT THE PREVIOUS OWNER REQUESTED A FRAME REPLACEMENT 60,000 MILES AGO IN 2014. TOYOTA DID NOTHING AND INSTEAD APPLIED A "CRC" OR CORROSION RESISTANT COMPOUND TO THE TRUCK. BASED ON WHAT I'VE READ ONLINE THE APPLICATION OF THIS COATING THIS CAN MAKE YOUR TRUCK INELIGIBLE FOR THE RECALL SERVICE THIS ISSUE EFFECTIVELY TOTALS THE TRUCK AS IT WON'T PASS A SAFETY INSPECTION WITHOUT RECTIFYING THIS ISSUE. I AM IN QUITE AN UNFORTUNATE SITUATION AS A RESULT AS THIS IS MY ONLY VEHICLE.

Type: Vehicle, Vehicle: 2005 TOYOTA TUNDRA, Manufacturer: Toyota Motor Corporation
Incident: Jun 2021
Apr 2021

DISCOVERED SEVERE RUST THROUGH ON THE UNDERSIDE FRAME.

Type: Vehicle, Vehicle: 2005 TOYOTA TUNDRA, Manufacturer: Toyota Motor Corporation
Incident: Apr 2021
Nov 2020

I PURCHASED TRUCK 2 YEARS AGO WITH A INSPECTION STICKER GOOD FOR 5 OR 6 MONTHS. WHEN INSPECTION WAS DUE I BROUGHT IT INTO HAVE IT INSPECTED. IT WOULDN'T PASS INSPECTION DO TO THE ADVANCED STATE OF CORROSION. I WAS TOLD THAT THERE WAS RECALL FOR FRAME REPLACEMENT DUE TO THIS PROBLEM AND ALL THESE TRUCKS ARE RUSTING OUT AND MANY STILL ON RD PUTTING LIVES IN JEOPARDY AS THOUSANDS ARE UNSAFE GOING DOWN HIGHWAYS. I BROUGHT IT INTO BERLIN TOYOTA IN PORTLAND ME ON RIVERSIDE DR. THEY BROUGHT ME TRUCK IN AND DID THE INSPECTION AND AGREED FRAME WAS NOT SAFE. THEY SAID MY TRUCK HAD TOO MANY MILES ON IT. I ASKED ABOUT THIS SAME TOYOTA THAT THEY BOUGHT BACK FROM A CUSTOMER WITH OVER A MILLION MILES ON IT ORIGINAL DRIVE TRAIN AND THEY HAVE BRAGGED THAT THESE TRUCK GO MORE THAN A MILLION MILES IF MAINTAINED PROPERLY. THEY KEPT TRYING TO TALK ME INTO BUYING A NEW TRUCK AND WERE ADAMANT ABOUT MY MILES BEING TOO HIGH. 220,009 MILES PLUS OR MINUS THIS WAS JUST OVER A YEAR AGO. I EXPLAINED TO THEM THAT I STILL OWED CLOSE TO 10,000 FOR THIS VEHICAL AND THAT THEY NEEDED TO STAND BEHIND IT. WELL LEFT EMPTY HANDED AND WENT BACK TO MY MECHANIC AMD TOLD HIM WHAT WAS SAID. HE INFORMED ME THAT THAT WAS RIDICULOUS BECAUSE HE HAD A CUSTOMER COME IN LAST WEEK THAT JUST HAD THEIR FRAME REPLACED AT 300,000 MILES AND IM JUST GETTING BLOWN OFF BY THEM. A YEAR LATER AMD I CANT EVEN GET TOYOTA TO RESPOND. THEY KEEP SENDING ME RECALL INFO ABOUT AIRBAG RECALL BUT WON'T ACKNOWLEDGE THE FRAME RECALL. ABOUT TWO WEEKS AGO MY MECHANIC CALLED ME TO SEE IF THEY REPLACED MY FRAME YET AND TOLD HIM NO. HE SAID THAT REALLY STRANGE BECAUSE HE'S HAD 3 CUSTOMERS OVER PAST 6 MONTHS WITH SAME TRUCK SAME YEAR AMD THEY WERE ABLE TO GET THEIR FRAMES REPLACED BY TOYOTA AND THEIR MILEAGE WAS AROUND THE SAME WITH THE EXCEPTION OF ONE BEING ALMOST 290,000. IM A SINGLE PARENT WITH CHILDREN AND IM MAKING PAYMENTS ON THIS.

Type: Vehicle, Vehicle: 2005 TOYOTA TUNDRA, Manufacturer: Toyota Motor Corporation
Incident: Jan 2019
Nov 2020

TL* THE CONTACT OWNS A 2005 TOYOTA TUNDRA. THE CONTACT STATED THAT WHEN THE VEHICLE WAS INSPECTED, HE LEARNED THAT THE VEHICLE WAS SEVERELY RUSTED. THE CONTACT CONTACTED DCH AUTO GROUP (955 U.S. 9, SOUTH AMBOY, NJ 08879; (877) 324-2886) WHO INFORMED THE CONTACT THAT PARTS OF THE VEHICLE HAD RUSTED THROUGH AND THE VEHICLE WAS NOT SAFE TO DRIVE. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE ISSUE AND OPENED CASE. THE APPROXIMATE FAILURE MILEAGE WAS 193,000.*DT *TR*DT*JB

Type: Vehicle, Vehicle: 2005 TOYOTA TUNDRA, Manufacturer: Toyota Motor Corporation
Incident: Aug 2020
Oct 2020

I RECENTLY PURCHASED THIS 2005 TUNDRA AND LATER FOUND OUT THAT THE FRAME OF THE VEHICLE WAS MASSIVELY RUSTED AND WILL NEED TO BE REPLACED. THIS VEHICLE WAS PART OF THE TOYOTA FRAME RECALL BUT WAS NEVER REPLACED AND AFTER CONTACTING TOYOTA THEY ARE TELLING ME THAT THEY WILL NOT REPLACE THE FRAME. TOYOTA SAID THE FRAME WAS 'TREATED' IN 2015 AND THAT SHOULD'VE TAKEN CARE OF ANY ISSUES. GIVEN THE PHOTOS THIS RUST HAS BEEN BUILDING FOR YEARS. THIS VEHICLE IS NOT ONLY DANGEROUS TO DRIVE BUT IS EFFECTIVELY USELESS. CONSIDERING IT ONLY HAS 77,000 MILES ON IT THIS LEVEL OF RUST SHOULD NOT BE PRESENT. *TR

Type: Vehicle, Vehicle: 2005 TOYOTA TUNDRA, Manufacturer: Toyota Motor Corporation
Incident: Aug 2020
Aug 2020

FRAME UNDERNEATH AT SWAY BAR AND SURROUNDING AREA IS RUSTED OUT. IT COULD BE A HUGE SAFETY HAZARD. THIS IS ON THE RECALL LIST. I AM REQUESTING THIS BE FIXED.

Type: Vehicle, Vehicle: 2005 TOYOTA TUNDRA, Manufacturer: Toyota Motor Corporation
Incident: Jan 2020
Aug 2020

MAIN FRAME OF THE 2005 TUNDRA IS ROTTEN FROM RUST AND A CHUNK OF THE FRAME HAS FALLEN OUT. SEE PICTURE. I CONTACTED LOCAL TOYOTA DEALER AND THEY SAID THERE IS NOTHING THEY CAN DO AS RECALL HAS EXPIRED AND TOYOTA CORPORATE WILL NOT DO ABSOLUTELY NOTHING. THIS TUNDRA WAS SUPPOSED TO BE SPRAYED IN 2014 AS PART OF THE "FIX" BUT THE FRAME IS RUSTING AND ROTTING APART. MORE SIGNS OF ROTS ARE VISIBLE ON THE FRAME.

Type: Vehicle, Vehicle: 2005 TOYOTA TUNDRA, Manufacturer: Toyota Motor Corporation
Incident: Dec 2019
Jul 2020

2005 TUNDRA WITH MAJOR FRAME RUST. TOOK IT IN DURING THE ORIGINAL RECALL WHERE THEY SPRAYED THE FRAME WITH A "RUST PREVENTATIVE COATING" WHICH FELL OFF IN A YEAR. THE FRAME IS NOW DANGEROUSLY RUSTY AND TOYOTA REFUSES TO DO ANYTHING MORE. TOYOTA NEEDS TO BE HELD RESPONSIBLE FOR REPLACING ALL OF THE AFFECTED FRAMES, NOT JUST THE ONES THAT DIDN'T PASS THEIR "INSPECTION" BACK WHEN THE ORIGINAL RECALL HAPPENED. THE RUST THROUGH PROBLEM IS A VERY WELL KNOWN ISSUE AND THERE ARE THOUSANDS OF TUNDRAS AND TACOMAS ON THE ROAD THAT ARE DANGEROUSLY RUSTY BECAUSE OF TOYOTA'S FAITHLESS RESPONSE TO THE PROBLEM. TOYOTA NEEDS TO BE FORCED TO REPLACE THE REMAINING FRAMES THAT WERE PART OF THE RECALL.

Type: Vehicle, Vehicle: 2005 TOYOTA TUNDRA, Manufacturer: Toyota Motor Corporation
Incident: Jul 2020
May 2020

THE VEHICLE WILL NOT PASS INSPECTION DUE TO FRAME FOR. THE BODY AND ENGINE ARE IN GREAT CONDITION FOR THE AGE. AN UNDERCOATING WAS APPLIED BUT DID NOT PREVENT THE RUST FROM SPREADING. TOYOTA HAS REPLACED MANY FRAMES FOR THIS SAME REASON AND SHOULD INCLUDE THE '04-'06 MODEL YEARS TO ENSURE ALL OWNERS OF TRUCKS WITH FAULTY FRAMES ARE SAFE. *TR

Type: Vehicle, Vehicle: 2005 TOYOTA TUNDRA, Manufacturer: Toyota Motor Corporation
Incident: Jan 2019

Trend Over Time

Complaints by year

Quick Summary

The 2005 Toyota Tundra has 60 Structure complaints on file. 1 crashes have been reported. Review the timeline above for detailed owner experiences.