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Frame Rust problems of the 2003 Toyota Tacoma



19 problems related to frame rust have been reported for the 2003 Toyota Tacoma.

car   Frame Rust problem 1
Failure Date: 07/14/2014

This truck is only 11 years old and the frame is rusted out. There is a hole about 12 inches long in the frame rail, on the right side, which caused my shock mount to break in the rear of the truck. I called Toyota and they won't do anything about it. I told them I would never buy another Toyota. This frame should last longer than 11 years.

car   Frame Rust problem 2
Failure Date: 06/11/2014

The contact owns a 2003 Toyota Tacoma. The contact stated that upon inspection, it was discovered that the frame was rusted. The vehicle was taken to the dealer, who confirmed that the frame had rusted. The vehicle was not repaired. The manufacturer was made aware of the failure. The failure mileage and the current mileage was 40,000.

car   Frame Rust problem 3
Failure Date: 05/10/2014

The contact owns a 2003 Toyota Tacoma. The contact received notification of NHTSA campaign id number: 05v225000 (suspension) and stated that an independent mechanic before the notification of the recall sprayed the undercarriage. The dealer informed the contact that the recall repair would not be honored due to the coating of the undercarriage. The vehicle was taken to an independent mechanic, who diagnosed that the entire frame was rusted and corroded and may fracture. A lift plate inspection was performed and it was diagnosed that the frame was covered with undercoating and the lift plate was unable to be repaired due to the rust. The vehicle was not repaired. The manufacturer was notified of the failure. The approximate failure mileage was 75,880.

car   Frame Rust problem 4
Failure Date: 04/25/2014

The contact owns a 2003 Toyota Tacoma. The contact stated that upon inspection, it was found that the frame was rusted. The vehicle was taken to the dealer where the failure was confirmed. The vehicle was not repaired. The manufacturer was contacted about the failure. The failure mileage was 94,650. The VIN was not available.

car   Frame Rust problem 5
Failure Date: 04/14/2014

The contact owns a 2003 Toyota Tacoma. The contact stated that while the vehicle was being inspected by a private mechanic, it was found that the frame was rusted. The vehicle was taken to the dealer who confirmed the failure. The vehicle was not repaired. The manufacturer was not contacted about the failure. The failure mileage was 180,000.

car   Frame Rust problem 6
Failure Date: 03/31/2014

The contact owns a 2003 Toyota Tacoma. The contact stated that while the vehicle was being taken to a dealer for an oil change, the mechanic noticed that there was a rust hole that had rusted through the frame near the right rear passenger's side. The diagnosis was that the frame needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the issue. The approximate failure mileage was 118,500. The VIN was unavailable.


car   Frame Rust problem 7
Failure Date: 09/10/2013

The contact owns a 2003 Toyota Tacoma. The contact stated that the vehicle was taken to the dealer for service under a NHTSA campaign I. D. 12v542000 (tires) however, the dealer could not remedy the recall due to excessive rust on the frame. The dealer advised that there was a previous recall for an undercoating spray to prevent frame rust. The contact stated that the vehicle received the treatment but it still did not prevent the frame rust, which the dealer stated would need to be replaced. The vehicle was not repaired. The failure mileage was 106,000.

car   Frame Rust problem 8
Failure Date: 07/03/2013

The contact owns a 2003 Toyota Tacoma. The contact stated that the frame was rusted and dropped five inches. The vehicle was taken to the dealer for diagnosis where they deemed the vehicle unsafe to drive. The vehicle was not repaired and the manufacturer was notified. The approximate failure mileage was 104,000.

car   Frame Rust problem 9
Failure Date: 12/27/2012

Toyota has recalled my truck due to a rusted out frame. The Toyota dealership has elected to replace my frame with a new frame. This large procedure has left me insecure about the outcome. This truck is now 10 years old and as soon as the start wrenching on all the system components to disassemble and re assemble my truck I am afraid that they shorten the life of existing components due to added wear and tear. The dealer will need to remove and reinstall brake lines and gas lines that have been set in place and have extensive corrosion this will lead to premature failure and unsafe operation. Most mechanic know that a rusted and set bolt that has not been moved for 10 years has a 50% chance of removal. In order to remove such a "stuck" bolt they will need to apply heat and impact and may weaken the existing parts, steel, and bolts to lower levels out of tolerance that the vehicle as designed originally. Additionally, this service is completed in a location with out the controls, quality assurance and testing that is in place in a factory where new vehicles are built. There is uncertainty that this vehicle will be assembled, tested, and inspected according the the manufacturer's guidelines for a factory produced vehicle. This leads to uncertainty that the vehicle will not operate within the intended manufactures guidelines for safety, roll over protection, and crash performance. I propose that a total frame recall and replacement (or any large integral part that will impacted the vehicle operation) on any vehicle shall not be allowed given the uncertainty described.

car   Frame Rust problem 10
Failure Date: 07/01/2012

The contact owns a 2003 Toyota Tacoma. The contact stated that the frame was severely rusted, exhibiting aa large hole. The vehicle was taken to a dealer where they advised him that the frame needed to be replaced. The manufacturer was contacted and offered no assistance. The vehicle was not repaired. The failure mileage was approximately 80,000. The current mileage was approximately 84,000.


 
car   Frame Rust problem 11
Failure Date: 04/02/2012

Tl- the contact owns a 2003 Toyota Tacoma. The contact stated that upon inspection, it was found that the spare tire carrier and subframe was rusted. The contact mentioned that the vehicle was previously repaired under NHTSA campaign id number: 12v542000 (tires). The vehicle was not diagnosed or repaired. The manufacturer was notified of the failure. The approximate failure mileage was 100,000. Dyd.

car   Frame Rust problem 12
Failure Date: 07/20/2011

Rust perferation on 1998 to 2004 Toyota Tacoma frames and undercarages, the dealer stated was due to improperly manufactured frames. Toyoa customer care told me that the voulntery frame recall on my 2003 Tacoma for frame rust expired in March of 2011 and they would not do anything to correct the problem. The frames of certain year Toyota Tacoma are defective and were not propery made and are subject to rapid rust perforation. Toyota should be required to correct the problem. Their voluntary prograam should be made mandatory.

car   Frame Rust problem 13
Failure Date: 06/08/2011

Tl- the contact owns a 2003 Toyota Tacoma. The contact stated that the entire frame rusted. The vehicle was taken to an authorized dealer for diagnosis and the vehicle was not repaired. The manufacturer issued a voluntary recall related to the structure; however, the recall expired. The manufacturer was notified of the problem. The approximate failure mileage was 96,000. Mah.

car   Frame Rust problem 14
Failure Date: 08/10/2009

The contact owns a 2003 Toyota Tacoma. While the contact was having his vehicle serviced, he was informed that the frame was rusting. The vehicle has not been diagnosed by the dealer. The current and failure mileages were 53,000.

car   Frame Rust problem 15
Failure Date: 05/05/2009

Tl-the contact owns a 2003 Toyota Tacoma. The contact stated that he looked at the vehicle and noticed that the sub frame had rusted. The vehicle was taken to the dealer for inspection and they stated that the frame needed to be replaced. The vehicle was not repaired. The manufacturer was notified. The failure mileage was 60,000. Ap.

car   Frame Rust problem 16
Failure Date: 01/13/2009

Synopsis of problem: the frame of the Tacoma was fabricated with insufficient corrosion protection, particularly inside the boxed section of frame under the midsection of the truck. The frame is literally rusting from the inside out. What happens is, as the frame rusts on the inside of the boxed section, the rust flakes drop onto the bottom of the boxed section. These rust flakes then plug the weep holes in the frame so that moisture is not allowed to drain out the interior of the boxed section, thereby exacerbating the potential for corrosion. So what is happening is the bottom of the boxed section of frame is rusting out due to the build-up of moisture and the accumulation of rust flakes plugging off the weep holes. The rust flakes are 1/8? deep on the bottom of my boxed section of frame. Basically the bottom 20% of Tacoma frames are rusting out. What is particularly dangerous about the bottom of the boxed section of frame becoming compromised by corrosion, is the bottom of the boxed section is where the bracket for the rear leaf spring is attached. As the boxed section corrodes, there is less and less material supporting this major suspension bracket. The design of this bracket must be analyzed by your NHTSA independent engineer. I strongly believe that it doesn?t take much frame corrosion to severely compromise the integrity of this welded leaf spring bracket. If this bracket fails, then the front of the leaf spring comes free, the rear axle comes out of alignment, which could cause the operator to lose control. This is a major safety issue! I also can't help but wonder that since the frame is an integral part of the vehicle's safety system, what does a severely corroded and weakened frame do to the level of crash protection offered by the vehicle? if NHTSA?s independent engineer finds that the frame does play a major role in the crash protection offered by the vehicle, then the NHTSA will have no choice but to force Toyota to do a recall.

car   Frame Rust problem 17
Failure Date: 12/31/2008

I am the owner of a 2003 Toyota Tacoma with approximately 29,000 miles, living in the northeast. The frame and the undercarriage of the vehicle have extensive rust from front to rear. I believe the frame is rusting from the inside out and will continue to do so. At this point, the transmission shield and the fuel tank shield are in danger of falling off of the vehicle. The leaf springs are so corroded that they no longer function properly. The exhaust system and muffler are completely rusted out.

car   Frame Rust problem 18
Failure Date: 06/01/2008

Excessive frame rust on 2003 Toyota Tacoma.

car   Frame Rust problem 19
Failure Date: 06/26/2007

The contact owns a 2003 Toyota Tacoma. When entering the vehicle, the contact noticed rust on the frame. The vehicle was taken to the dealer and they predicted that the frame would fail within the year. The contact received a recall notice from the manufacturer regarding the frame failure. The vehicle was taken to the dealer and they conducted a test by taking a hammer and striking the rust spots to see if the hammer would go completely through. The failure could not be duplicated, which meant that the vehicle was not completely failing. The contact was informed to bring the vehicle back for inspection by a regional inspector. The contact feels that the issue needs to be remedied before a crash occurs. He called the manufacturer and was informed that a regional inspector would call him to schedule an appointment for further inspection. The failure mileage was 45,000 and current mileage was 61,200.


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