Frame Rust problems of the 2004 Toyota Tundra

34 problems related to frame rust have been reported for the 2004 Toyota Tundra. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2004 Toyota Tundra based on all problems reported for the 2004 Tundra.

car   Frame Rust problem 1
Failure Date: 01/01/2018

Rusted holes in frame.

car   Frame Rust problem 2
Failure Date: 09/18/2017

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.

car   Frame Rust problem 3
Failure Date: 06/09/2017

I purchased my 2004 Tundra from a Subaru dealer last summer and did not realize it was included in the many trucks which had premature frame rust. Toyota admitted it was an issue and stated that the previous owner had undercoating put on the truck paid for by Toyota, however, clearly this was ineffective and a temporary band-aid for inferior metal. Toyota stated that they would not do anything to correct this problem, and as a college student, I need access to a safe vehicle. I am afraid to drive this truck as if it is struck by another vehicle, I do not believe it would withstand the impact due to severe frame deterioration. I understand the truck is from 2004, however, the rust on this frame is beyond a normal rate. Meanwhile, I am out $16,000 and the rust has overtaken the truck greatly within the past year. Toyota still refuses to help despite my gas tank needing to be replaced and my pictures of all of the deterioration. Despite doing my research and seeing how well-maintained this truck was, the frame itself has rusted beyond recognition and yet, the other parts remain relatively intact. This vehicle is otherwise in extraordinarily good shape and is and was well-maintained. It only had 58,000 miles on it when purchased and still has less than 80,000 miles.

car   Frame Rust problem 4
Failure Date: 05/23/2017

I have excessive rust on my frame. I has holes in frame and almost rusted in two. Toyota will not do anything about issue. Not sure what to do about it. The truck runs great and the body is in great shape. Frame is in bad condition.

car   Frame Rust problem 5
Failure Date: 05/05/2017

My Tundra was under the frame rust recall in 2014. Toyota's claim was that the salt from the roads caused the severe corrosion. As we all know this was actually from the use of sub standard steel in the manufacturing process. My frame was actually DE laminating, not just simple surface rust. When I had taken it in for inspection all that was done was wire brush the frame and spray with an undercoating. Now just a little under three years later the coating is peeling of along with more layers of metal. Most of the people I know with tacomas and Tundras had their frames replaced when theirs were taken in. So now I have a truck that is no better than it was before. Also most of the chassis components are rusting out prematurely as well. My spare tire winch mechanism (carrier) bracket was about to rust through, luckily I caught this before I possibly could have dropped my spare when traveling on the interstate. I would appreciate someone from nhtsb taking a look at my vehicle to see the extent of what I am talking about. My vehicle only has 67,000 miles on it. I did contact Toyota service about this, but their answer was you have what you have and they will not do anything further. I'm sure I'm not the only one in this situation. My frame should have been replaced. Thanks.

car   Frame Rust problem 6
Failure Date: 03/10/2017

I just got off the phone with a case manager name marquita from Toyota. I had called three days earlier and was told a case manager would call. I received no phone call, and had to call them myself. My Tundra is one of the vehicles affected by the lack frame protection resulting in a severely rusty frame. I had the frame inspected by a local Toyota dealer and was told that the undercoating that was meant to solve the problem was poorly applied. Huge chunks are my frame are falling off and the frame is exposed causing it to continue to rust. The master technician brought me back to show how the frame was not originally prepped and the undercoating was thinly applied. So back to the conversation with the case manager. Marquita proceeded to tell me the undercoating was a one time remedy to the frame rust problem. Whether or not the undercoating was done well or not, Toyota is not willing to rectify a poorly done "solution". The same rusty frame is under all the slime they applied and now it is going to continue to get worse. This is a known issue, and I believe Toyota sued the manufacturer of the frames. And me and the other owners are left to rust.

car   Frame Rust problem 7
Failure Date: 11/19/2016

In febraury 2014 I received a recall for the frame rusting on my truck, I brought the truck to Toyota of keene for inspection and they undercoated the frame. They did a lousy job of undercoating and I complained to Toyota, because they did what they were instructed to do they would not review or reinspect the vehicle. My Tundra had 58,970 miles on it when it was undercoated for the rust issue, it now has 66,406 miles on it. The whole frame is rusted, so bad when I drove down my driveway big patches of rust fell off of it. Open the hood and you see nothing but rust. I do not feel like this vehicle is safe for the road but because of my health situation I cannot afford to get a new vehicle. All I want is the vehicle to be repaired the way it should have been in the beginning. The spare tire holder has rusted to the point of loss of the use, carrying the spare tire in the bed on the back of the truck, the gas tank door rusted right off so I had to get a new door, I just need someone to help resolve this unfortunate rust bucket of a situation.

car   Frame Rust problem 8
Failure Date: 11/15/2016

Tl-the contact owns a 2004 Toyota Tundra. The contact stated that the vehicle was taken to an independent mechanic for schedule maintenance and was advised that the repairs can not be performed because the frame was severely rusted. The contact also stated that the vehicle was evaluated by the dealer two and half years ago and the diagnosis was that the frame was alright. The vehicle was diagnosed a second time and the diagnosis rendered by the dealer was that it was not severe enough for the frame to be replaced. The manufacturer was notified of the failure. The contact was advised by the manufacturer that the recall had ended. The vehicle was not repaired. The approximate failure mileage was 135,000. Bp.

car   Frame Rust problem 9
Failure Date: 11/12/2016

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.

car   Frame Rust problem 10
Failure Date: 10/19/2016

Observing excessive frame rust and frame decay. Concerned about structural safety based on the significant frame degredation.

car   Frame Rust problem 11
Failure Date: 09/08/2016

Frame rust, the entire frame is rusted and the spray of the under carriage is falling off and now rusting even more.

car   Frame Rust problem 12
Failure Date: 07/13/2016

Found 4 inch rust hole through frame on 2004 Tundra with 80,000 miles that was treated with the coating in 2014. Toyota corporate said there is nothing they will do to fix it as the recall or whatever expired in 2015. How convenient. Frame rot is a safety issue! this is a family vehicle! if not repaired, the frame will fail.

car   Frame Rust problem 13
Failure Date: 07/06/2016

Rusted rear differential. Rusted frame at front right sway bar. Can't pass inspection. Seems to be a common problem just like the 2003 model. I still have payments on this vehicle I can't drive.

car   Frame Rust problem 14
Failure Date: 06/29/2016

The contact owns a 2004 Toyota Tundra. The contact stated that the vehicle was previously serviced per a NHTSA campaign related to the frame rusting; however, the failure recurred. The manufacturer was not notified of the failure. The failure mileage was 109,265. The VIN and NHTSA campaign number were not available.

car   Frame Rust problem 15
Failure Date: 06/29/2016

Frame recall- my 2004 Tundra was recalled for the frame rusting out. Toyota deemed that a new frame was not needed and did the crc treatment which is absolute junk and only causes the frame to rust even worse. Rear differential is completely rusted and leaking fluid. Problem also with catalytic converters.

car   Frame Rust problem 16
Failure Date: 10/16/2015

Excessive frame rust causing failure to pass state inspection.

car   Frame Rust problem 17
Failure Date: 10/01/2015

Tl- the contact owns a 2004 Toyota Tundra. The contact stated that while having routine maintenance performed on the vehicle the contact was informed by the technician that the vehicles frame had rusted and was corroding. The vehicle was not diagnosed nor repaired. The manufacturer was made aware of the failure. The failure mileage was 200,000. Wh.

car   Frame Rust problem 18
Failure Date: 09/21/2015

Frame rusted through unsafe to drive. Received very first letter in July about a recall. It is September 21, 2015 and the recall ended August 31, 2015.

car   Frame Rust problem 19
Failure Date: 04/14/2015

Toyota recalled my Tundra for a rusted frame. Dealer took possession of the vehicle in April. They provided a rental car, but no other update or contact until a week ago when the frame arrived. Now nearly complete, they want to charge me $8000 for additional parts not covered by the recall which they claim is necessary to make the vehicle pass inspection and roadworthy yet many of these parts were unaffected prior to the recall. At no time did Toyota ever inform us of additional costs not covered by the recall. Two of the items are critical to the value and drivability of the car. They include the rear axle and differential which I believe failed due to the same rusted issues as the frame. The additional parts affected were the brakes. The front brakes seized from 6 months of non use and maintenance by the dealer, the rear brakes were failed by fluid leak from rear axle while in possession of the dealer for 6 months. In short, after getting a new frame, the dealer was holding trying to charge $8000 in extra repairs or they would return me a truck that had a new frame but was still inoperable in the condition under which it was stored by the dealer. The dealer and Toyota were responsible for maintaining the vehicle and returning it in as good or better condition than they received it, but instead it lost 1005 of its value. I cant drive it, I cant sell it. It has a new frame but now has no differential or brakes it has lost all marketable value, where it could have been traded in or sold prior to the "frame replacement" that was supposed to right all the wrongs" of Toyota's doing. I have full service records showing responsible ownership of the truck for the last 10 years. Needs to make it right and fix my truck so I can drive again, or buy me out, or offer me a trade allowance that is fair and equitable. This Toyota case number is 1504140934.

car   Frame Rust problem 20
Failure Date: 04/01/2015

2004 Toyota Tundra has significant frame rust. Took to dealer they sprayed it with an under coating which within 1 year all fell off due to rust underneath the coating. The Toyota dealer then re sprayed and now its falling off after the vehicle say in a garage without being driven. Also the rear axel housing rust straight through and now doesn't old any fluid. I filed a case with Toyota and they said they completed there part of the recall. Which was apparently paint over the rust.

car   Frame Rust problem 21
Failure Date: 03/01/2015

Frame has rust holes. I call Toyota and told me there is nothing they can do about it case closed.

car   Frame Rust problem 22
Failure Date: 04/18/2014

Frame recall- my 2004 Tundra was recalled for the frame rusting out. Toyota deemed that a new frame was not needed and did the crc treatment which is absolute junk and only causes the frame to rust even worse. I want a new frame installed by toyata and any other rusty part- all should be replaced free of charge.

car   Frame Rust problem 23
Failure Date: 10/16/2013

Tl-the contact owns a 2004 Toyota Tundra. The contact stated that the vehicle frame was rusted. The vehicle was taken to a dealer for inspection. The mechanic stated that there was no holes in the frame and painted the frame with crc paint. The contact stated that the remedy did not repair the failure, and the rust returned. The vehicle was not repaired. The manufacturer was notified of the failure. The approximate failure mileage was 58,000. Mf.

car   Frame Rust problem 24
Failure Date: 07/26/2013

The frame has severe rust. Also rear differential is leaking fluid through the steel bowl.

car   Frame Rust problem 25
Failure Date: 06/30/2013

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 ther was a recall for 2000-2003 Tundras for the same issue but my 2004 was not included in the recall.

car   Frame Rust problem 26
Failure Date: 12/12/2012

My 2004 Tundra has a rusted frame that is not safe. The truck has 48,000 miles on it and the frame has rust holes through it. This is not normal surface rust. The truck has no other rust issues. Toyota needs to recall this vehicle.

car   Frame Rust problem 27
Failure Date: 11/15/2012

The contact owns a 2004 Toyota Tundra. The contact stated that while replacing the front passenger side tire, it was noticed that approximately six inches of the frame was extremely rusted. The manufacturer was not made aware of the failure. The vehicle was not repaired. The approximate failure mileage was 157,000. The VIN was not available.

car   Frame Rust problem 28
Failure Date: 01/28/2012

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.

car   Frame Rust problem 29
Failure Date: 01/01/2011

The contact owns a 2004 Toyota Tundra. The contact stated that the spare tire fell from the vehicle due to the carrier being rusted. In addition, he noticed that the frame was severely rusted. The vehicle was taken to a dealer where they advised him that the carrier was rusted and needed to be replaced. Also, the frame was not completely corroded. The vehicle was not repaired. The manufacturer was contacted and offered no assistance. The failure mileage was approximately 80,000. The current mileage was approximately 123,000.

car   Frame Rust problem 30
Failure Date: 12/21/2010

Tl- the contact owns a 2004 Toyota Tundra. The contact stated that the frame was severely rusted and could possibly fracture in half at any time. The vehicle was taken to the dealer for diagnosis however, the vehicle was not repaired. The manufacturer was notified but offered no assistance. The vehicle was not repaired. The VIN was unavailable. The failure and current mileage was 55,000. Kmj.

car   Frame Rust problem 31
Failure Date: 03/10/2010

Tl-the contact owns a 2004 Toyota Tundra. The contact stated that the entire frame exhibited severe flaking rust, which separated in chunks. The corrosion became progressively worse over a period of time. The vehicle was inspected by an authorized dealer who stated that the frame rusted without any perforation. The vehicle was not repaired. The manufacturer was notified of the problem. The approximate failure mileage was 30,000. Kmj.

car   Frame Rust problem 32
Failure Date: 01/01/2010

The contact owns a 2004 Toyota Tundra. The contact stated that upon inspection, it was determined that the frame was rusted. The vehicle was taken to the dealer where it was confirmed that the frame was perforated due to rust. The vehicle was not repaired. The manufacturer was contacted. The failure mileage was not available.

car   Frame Rust problem 33
Failure Date: 09/13/2009

Frame rust.

car   Frame Rust problem 34
Failure Date: 07/15/2009

My 2004 Toyota Tundra double cab has an excessive amount of rust on the undercarriage. Because of this rust, the camber bolts cannot be removed to properly align the vehicle. I have been told that they will have to use heat to remove them, along with a lot of force, and in turn may do frame damage in the process. I have been quoted by my dealer $5,200 to fix the problem which initially started with a small shimmy in the steering wheel which grew into a big shimmy especially while towing. That quote does not include any possible charged from the body shop if damage to the frame should occur. I do not have $5,200 so I ended up with a new set of tires and half of an alignment because the camber bolts were not able to be removed. Here I am months later and my new tires are so bald on the front that I am actually seeing the tread showing through. I have always loved my Tundra, but all of this rust on the frame and undercarriage is very concerning regarding the longevity of my vehicle. I was told that Toyotas last forever. At this point I feel that my truck is dangerous to even drive but it is my only vehicle. I have owned and maintained many vehicles and never had rust issues like this, nor have I ever been faced with such a costly repair on a not so old vehicle. I am stuck in a bad place and just don't know where to go or what to do. I desperately need my truck. Without it I lose my source of transportation as well as my ability to earn a living. I just simply cannot afford. . . Meaning I just do not have this kind of money to bring my truck back to health. All of this stress and frustration is a result of this excessive rust. Included in the estimate is remove and replace camber bolts $1,957 --- steering rack boots 400. 00 alignment 90. 00---- driveshaft assembly $2,003---- rear u-joint $433. 00---- differential fluid $330. 00 it does not include any possible damage to the frame/body in their attempt to remove the camber bolts or another brand new set of tires.

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