Brake Disc Caliper Problems of Toyota Tundra - part 1

Tl the contact owns a 2018 Toyota Tundra. While driving 25 mph, the contact noticed an abnormal noise coming from the rear driver's side wheel. While approaching an intersection, the brakes seized without warning when the brake pedal was depressed. The contact exited the vehicle and noticed that the brake caliper was tangled in the wheel. The contact attempted to drive the vehicle with the emergency brake activated, but it caused more damage to the rim and rear driver's side wheel. Team Toyota of glen mills (1050 baltimore pike, glen mills, PA 19342, (484) 407-0835) diagnosed the vehicle and informed the contact that someone tampered with the brake system, which caused the failure. The vehicle was not repaired. The manufacturer was made aware of the failure and provided case number: 1906060300. The failure mileage was 13,900.

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The contact owns a 2007 Toyota Tundra. While the vehicle was parked, the contact noticed that the subframe underneath the vehicle was corroded, even though an anti corroding agent had been applied to the vehicle. In addition, the brake pads, rotors, and calipers had to be replaced prematurely on multiple occasions. The vehicle was taken to an independent mechanic and a dealer who both confirmed that the corrosion was past the point of repair and that a new subframe would be needed. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was 50.

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Upon routine brake change/inspection uncovered that brake caliper mounting bolt was completely deteriorated (Toyota part number to47814-0c010) permitting the entire brake caliper to move freely around rotor. Dealership noted vehicle is not safe to drive in condition until repair could be made. Reporting this as significant issue given that it is determined unsafe by Toyota dealer, directly effects ability to stop, and is happened to a low mileage vehicle not driven hard. Half inch caliper pins should not deteriorate.

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All four brakes were rendered almost inoperable due to corrosion of calipers, discs and mounts. Discovered when brake pedal required considerable effort to stop vehicle. Was told by maintenance manager at dealership that brakes could have failed at any time. Seems to be an engineering problem (steel components that rust) effecting low-usage vehicles.

The 2002 Toyota Tundra has known issues with the front rotors and pads and service bulletin about the problem for corrections to be made. I complained to the dealer about the problem in 2003 with maybe 20,000 miles if that. The problem was corrected under warranty, that is, the rotors and pads were replaced, so I was told, but with the same problematic parts that were issued with the truck. The calipers, which have been reported as undersized for the vehicle, were not touched. Eventually the shimy becames bad enough it negatively affects the brake system. Toyota knew of the issue but did not follow through in truly correcting the problem.

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Any speed above 40mph produces a violent shake/wobble from the front end. Going down a slope and /or applying the brakes makes the problem worse. This is the second time in 2 years that I have had to replace the rotors, calipers and pads at a considerable cost to myself. Both times the symptoms were the same and the cause was the same. The plungers on the right front caliper sticks and causes the pad to maintain contact with the rotor and overheating it causing the rotor to warp. The warp in the rotor produces the shaking which is extremely unsafe. I don't tow or haul heavy loads, I don't drive excessively fast nor do I use excessive braking, still the problem recurs.

2001 Toyota Tundra complaint: while I was driving in the city all of a sudden I lost 90% of my braking ability. After pulling over to the side and inspecting my front brakes I notice my left driver's side had fluid on the road and tire. Limping it home and on farther inspection the bracket that supports the flex line from the frame to bracket and the ridged line from the bracket to the brake caliper was rusted off, this caused the ridged line to fracture. After purchasing a new bracket I than needed to look at the passenger side to see exactly how to mount the new bracket, to my surprise the passenger side bracket was also rusted off. I am sure it would have been a short period of time before I loss my brakes again had I not inspected the passenger side. When notifying the dealer about it I was pretty much blown off as the only person with this problem there for I probably just imagined it. So I guess my complaint is recalling these trucks for an inspection of singular rust problem such as the spire tire bracket is a joke. These trucks are just simply road hazards and are going to get a lot of people killed if action is not taken to get these rust buckets off the road.

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The owns a 2001 Toyota Tundra. The contact stated that while driving downhill at approximately 30 mph on a mountainous road, the brakes were depressed and pulsated abnormally as the front end of the vehicle began to vibrate violently. The failure only recurred when the contact was driving downhill in combination to the brake pedal being engaged. The vehicle was taken to an authorized dealer, who stated that the rotors and calipers would need to be replaced. The vehicle had not been repaired. The manufacturer was notified of the defect. The approximate failure mileage was 60,000.

The contact owns a 2010 Toyota Tundra. The contact had to apply excessive pressure to the brake pedal in order to stop the vehicle. The vehicle was taken to the dealer where it was diagnosed that the calipers failed. The vehicle was repaired, but the failure recurred. The vehicle was taken to an independent mechanic where the failure could not be diagnosed. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was approximately 3,865.

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Took my 2002 Tundra to a local Toyota dealer for a second time to inspect frame after being told by an independent licensed mechanic that my frame was perforated/rotted, the rear end housing was leaking, the spare tire hanger was broken,(tire missing), all heat shields were either broken,loose or missing and front brakes were in need of being replaced again. Front brake rotors, pads and calipers were replaced 11/09/07. All of this had occurred since 05/06/2010 when the truck was last on his lift. Harr Toyota performed a frame inspection and verified all of the above failures. They also did the frame crossmember inspection in 01/10 and the truck passed. They specified that the frame failure was @lt rail/trans mt. They also said the rt ft sway bar link was broken, and noticed an exhaust leak. They declared that in spite of the frame failure it was safe to drive just don't do any offroading! so I guess that hitting a pothole would not be advised. ! they told me that the brakes were unsafe, and not covered under any recall. I am very upset at the condition/value of my truck. I am also very upset that NHTSA is letting Toyota get away with the "warranty enhancement" of replacing the frame only of these trucks. Toyota and its dealers denied the rust problem for years. My problem started when the vehicle was still under warranty, and I was blamed for the failure. In the years that Toyota has denied a problem with the Tundra, the frame rust has infected, most if not all, of the truck. Both bumpers are rotting off. The gas tank had to be patched (05/2010) because it was leaking fuel from a rust spot under one of the support straps. Toyota will replace other compromised parts at the owners full expense. In my opinion they are using the frame replacement to generate part sales and repair business to help defer costs. Nhtsa- please force a more comprehensive recall! !.

7/2007 purchased 07 Tundra w/maint plan&extended warranty 9/2010 4342miles southcoast Toyota-maintenance,we asked them to take a look at surface rust. They noted it and said was due to salt air 2/2012 6504miles southcoast Toyota to perform brake service. Apparently brake pad had fallen off due to corrosion of calipers & pins and they refuse to service the truck because it would be too much to repair but refuse to even give us estimate. They said the corrosion has compromised the safety of the truck, but not covered under warranty. We were told that we did not drive the vehicle enough and that's why it is rusted so badly all over (truck was driven locally at least 3 or 4 times a week by elderly couple). We requested a copy of field reps report, but they said it is proprietary info we do not have access to. Service manager rudely asked us to remove our truck from the dealership but we cannot drive it off because brakes not operating properly. Were told to take the 5 yr old truck with 6500 miles to the junk yard. During 2010 maintenance when they were aware of corrosion, we should have been advised of possible brake failure or weakened structure due to rust that would occur in less than two years time. Instead elderly couple continued driving vehicle until unsafe to drive without being advised of how severe of condition the truck is. They have lived by the beach (2 miles from dealership) for 30 yrs & owned a few trucks, never rust so bad. Toyota is fortunate that no one was hurt driving this vehicle & they should do what they can to take this unsafe truck off the roads. Instead they deny any possibility that the corrosion may be a defect & is allowing this truck to possibly end up being driven since they are willing to release it. Its obvious this is not the 1st Toyota known to have corrosion issue and though not perforation, the rust is an oversight by Toyota.

Tl-the contact owns a 2010 Toyota Tundra. The contact stated that while driving approximately 35 mph, the contact stated there was an abnormal smell emitting from the vehicle as the brakes seized without warning. The vehicle was taken to a dealer. The technician stated that the vehicle was operating as designed. The failure recurred. The vehicle was then taken to an independent mechanic, where it was diagnosed that the brakes, the rotors, and the calipers needed to be replaced. The vehicle was repaired. The manufacturer was notified of the failure. The failure mileage was 31,000. Pam.

The 2000-2003 model year Toyota Tundras have a known brake engineering defect. The front brake calipers are too small causing routine overheating of the front brake rotors. This condition warps the brake rotors and causes an unsafe and unpredictable brake response. Repeated re-surfacing or replacement of the rotors always results in the recurrence of the warpage due to the improperly sized front calipers. Toyota quietly issued a TSB in the early 2000's that mandated installation of larger calipers and replacement of other affected parts. This "fix" has not been common knowledge among affected consumers. This TSB not only acknowledges the original design flaw but contains specs and the specific remedy !.

Hi - in 2001 I purchased a 2000 Tundra and had major issues with the brakes some time later. After several contacts with Toyota corporate offices I was told I was out of luck. The rotors would warp and in 2003 Toyota increased the caliper/pad size to fix the problem. There was a TSB released to fix the older trucks but nothing was done to fix the pre 03 trucks. At one point several years after the trucks hit the road, Toyota said if your truck had under 30k miles they would fix the problem, by then all trucks had more miles than 30k at average yearly mileage rates. I believe people lives were at risk, and Toyota failed to address the problem for financial reasons. I repaired my truck myself as you can see in the attached file, and shared the economical fix with many web users with the same problems and frustration with Toyota. I would like to see Toyota admit they should have recalled the brakes, and repair or reimburse owners. I think my Toyota truck is a very good truck but was very disappointed in their handling of major safety issues. . Read more...

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2001 Tundra brakes failed to stop truck from hitting vehicle in front on a sudden stop on the interstate. Found out later that Toyota knew of defective brakes and issued TSB br004-002 to replace 191mm front brake calipers with larger 231 mm calipers within the warranty period, but did not notify owners of the defect. Only owners who complained of vibration when braking and early failure of front rotors and brake pads were offered the upgraded calipers, but only after repeated complaints. The upgraded calipers were eventually incorporated into the 2004 and later Tundras.

Excessive rust pretty much everywhere. Just had to replace the rear differential and associated parts because rust caused differential leak. Cost was over 3,500. Replaced rusted brake lines and calipers. Tailgate wire rusted and broke. Opening mechanism to tailgate is rusted and is extremely difficult (if not impossible) to open/close. Rear bumper is rusted through, and not safe to step on. Hitch receiver is completely rusted and cannot remove hitch now. Skid plate and brackets rusted through - skid plate fell off. Dealer just inspected the truck and will be replacing the entire frame because of excessive rust.

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Severe brake vibration. Replaced front brake pads, rotors & calipers (w/ oem parts) around 72k. At 92k truck developed a severe braking vibration both in the front & rear the steering wheel would shake so bad that it was hard to control the truck when braking/stopping. Again I replaced both the front rotors & calipers & had the rear brake pivots cleaned & lubed(at the dealership). Now 10k later I am again starting to experience the same braking problems & vibrations. I should have never had to replace my brake parts after 20k & I definitely should not be experiencing that same problems 10k later.

Front drivers side sway bar link is corroded through. No accident or injury but only because I knew what was going on after I saw the broken link and drove accordingly. After further investigation we find that the brake calipers are corroded beyond salvage and the frame has heavy rust in a number of areas. It is clear that this truck will be worthless in a few years due to the heavy corrosion and we will all be lucky if someone is not killed due to corrosion damage causing something to fall off and cause a wreck.

Toyota Tundra 2005 - when braking the front end shudders and moves back and forth. When front braking system was inspected the rotors had warped. Toyota issued a 2005 repair notification that brake rotors were warping but did not pose a safety problem. Toyota recommended repairs require replacement of the rotors, calipers, and brake pads. There is no guarantee that this will resolve the problem per the repair notification. My vehicle continues to shudder when applying the brakes with potential loss of control at highway speeds. I have not had the recommended repairs done since the estimated cost is $2200 per my local Toyota dealer.

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Front brake caliper corrosion leading to reduced braking capability.

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I own a year 2000 Toyota Tundra, which I purchased as a new vehicle. The truck has approximately 81,000 miles on it and has been garaged for the entire time that I have owned it. The underside of the vehicle has shown extreme rusting, especially the brake system which has failed twice due to corrosion. During the most recent brake failure I could not stop the vehicle while descending a hill and downshifted the transmission to slow down. Additional rust problems have included replacement of all front and rear brake lines, including the rear proportioning valve. The front rotor caliper pins have also seized due to rust. The emergency brake seized due to rust and was not operational. Both sway bar links and bushings failed due to rust. The heat shields around the muffler and catalytic converter rusted off the Tundra and may have posed significant safety hazards to drivers traveling behind me on the highway. These corrosion problems were reported to Toyota and the truck was inspected by a district service representative for frame rusting only (summer 2009). The other problems with the braking system, etc. Were completely ignored, even though I brought this to the service rep's attention. In addition, the district manager was contacted several months ago and has not addressed my concerns. All the above problems above were repaired at the local Toyota dealer, whose mechanics commented that the underside of the truck was severely corroded. Also, the repairs are documented in my vehicle's service history.

2002 Toyota Tundra front brake severe front end shimmy when braking,caused me to run off road into guard rail. Toyota refused to admit to front brake problem when in warranty and now out. Well documented problems with these calipers not enough deaths obviously to warrant recall.

The contact owns 2000 Toyota Tundra. The contact stated that when you start to slow down the front ends start to shake and make the vehicle harder to stop and control. The contact took the vehicle to the dealer and the brake pads were replaced twice by the dealer, but the problem was actually with the rotors, caliper and disc. Once they were replaced, the vehicle started to slow down properly. The dealer did not give a reason for the failure; however, they said they upgraded the rotors and the calipers to a larger size. The failure mileage was 160,000 and the current mileage was 214,000. Updated 04/05/lj the consumer was informed the rotors were too small. The rotors were warped which caused a vibration in the front tires when the brakes were applied after the vehicle had been driven for a short period of time. Updated 05/23/11.

My 2002 Toyota Tundra limited extended cab 4x4, v-8, has a pulsating brake pedal since I took delivery of it on 2/1/02. Every year when the truck was taken to the dealership for the PA. State safety inspection & emission inspection, I complained of this problem and on several of my dealer invoices this complaint is noted. At one point I took a TSB,(technical service bulletin) into the service manager and showed him that Toyota had a problem with the front brake pads,calipers, and rotors on the Tundra trucks,(2000 thru 2005). The original front brake pads,calipers and rotors were too small for this size truck causing the brakes to heat up and warp the rotors. Toyota was trying to correct the problem by offering an updated front brake kit, which consisted of larger pads and calipers. I was told by the service manager that my truck already had this updated brake kit installed. This was absolute lie on his part because after reviewing the TSB and looking at the pictures of the old style pads and calipers verses the updated pads and calipers, it was obvious that my Tundra had the old style and TSB was dated 9/12/02 and my truck was taken delivery of on 2/01/02. On 7/7/08, I took my Tundra to the dealer for inspection and was told by the service manager that my truck needed brake pads and new rotors because of the pulsation caused by rotors. He told me that Toyota had a problem with these brakes because they were to small for this size truck. My total bill for the pad,rotor,and inspections came to $498. 84. When I told the dealership about the brake TSB on my truck they said it did not qualify for the TSB and there was nothing they could do. . Have documented proof that indeed my truck did qualify for the TSB. I called Toyota customer assistance and all I got from them was a lot negative attitude and they told me it was a dealer problem. Basically, they told me to"go scratch". This brake problem is going to lead to heated brakes that will not stop the truck.

Vehicle purchased 5/2002. Brakes pulsating & vibration while braking have resurfaced numerous times, had front rotors replaced and then resurfaced again after the replacement, yet the pulsating and vibrations continue to recur approx 3-6 miles after any repair work. Problem seems to be rear drum and front discs not working cohesively. Front discs have all the breaking burden. No failures yet or injuries because we are so worried that we brake far ahead of time to ensure we stop on time with all the vibration and shimmying going on.

I purchased a 2001 Toyota Tundra in March of 2007. I have had problems with the front brakes warping the rotors. I have since found that there was a service bulletin on the brake problems in 2002 on this model. The bulletin required a larger brake caliper and pads because the system was to small to handle the truck weight. The factory installed system was heating up and causing the problem. My contention is this should be a safety issue since factory installed brakes are not large enough to handle the truck. I have taken the truck to mechanics on three occasions. Rotors have been turned, but the problem continues. Mechanics from these locations and from a Toyota dealership advise me the problem will continue until the bulletin called for calipers are installed. With the problem as it is, the truck is hard to stop when breaking from 50 mph and up.

Breaks on Toyota Tundras are defective and Toyota knows about it as stated in TSB #br004-02. My front brakes have worn out prematurely. The only reason that I have not experienced the problem sooner is that I mainly use the truck for occasional long distance highway trips. I am experiencing vibration when applying the brakes and they wore out prematurely. Numerous other customers have complained about this issue as well. Based on some of these additional complaints, Toyota is doing everything possible to avoid fixing the problem. . Read more...

I bought a 2001 Toyota Tundra in July of 2004. The truck had 64,000 miles. I have replace my brakes and had my rotors turned many time. The truck continually warps the rotors and has severe shaking when I brake. Toyota sent out a TSB only to cover the warranty vehicles. They know they have a problem but refuse to fix them. I have done my research and there are thousands of people out there with the same problem. The only fix is to install oversized rotors and calipers and new brake lines at the cost of $2,000. 00 plus. Toyota knows there is a problem and will do nothing about it. Please help!.

Carrying a heavy load in mountain terrain. The front brake rotors rapidly warped, leading to violent shaking, inability to stop and near-loss of control. Brake rotors were turned and pads upgraded to ceramic. Going through the mountains without a load caused the rotors to warp again, once more leading to inability to stop and near-loss of control. The front brake assemblies were completely replaced by pellman's automotive in boulder, CO, with the mechanic stating that the original Tundra brakes were inadequate. Parts unavailable.

I am the owner of a 2000 Toyota Tundra with dangerous pulsating, vibrating front disc brakes. I first brought this problem to the attention of my dealer on July 31, 2002. The vehicle had 12,894 miles at the time. The warped front rotors were resurfaced and the brake pads replaced. Neither the front rotors nor the calipers were replaced. I was informed at the time that the maximum amount had been machined off the rotors. The problem quickly reappeared and has gradually worsened over the last 16,000 miles. The car is driven very lightly and has towed a horse trailer for approximately 200-300 miles. Today the truck has 28, 600 miles and is very dangerous to drive on any road, but particularly dangerous on longer downhill grades. I brought this to the attention of the dealership early in June 2006 when I had defective oxygen sensors replaced. They checked for recall notices and found none. Curiously, they did not notify me of the technical service bulletin issued in September of 2003. Basically, they said it would cost me a lot of money to have them repaired. In light of the fact that this problem results from defective front brakes, and this defect existed at the time the vehicle left Toyota's possession, I asked Toyota to properly repair the brakes before serious property damage or personal injury occurs. Toyota responded to my request on June 15, 2006 as follows: "we have checked your vehicle identification number (VIN#) and there are no outstanding special service campaigns on your vehicle at this time. The warranty for your braking system (excluding wear items) is 3 years or 36,000 miles, whichever comes first, from the date of first use for your vehicle. Based on the VIN (vehicle identification number) you provided. Your warranty coverage started on 3/15/2000. Your vehicle is currently outside these warranty parameters and we are unable to assist with the cost of this repair. ".

2001 Toyota Tundra front brake shimmy so severe that truck was unsafe to drive. Began at approximately 40k miles and progressively got worse until entire front brake rebuild required costing over $2,200 at 56k miles.

Bolt holding driver side brake caliper (front) was found missing. This bolt is one of four that hold the two caliper sides (inner and outer) together. Called local Toyota dealership and was told I had to buy the complete caliper assembly for $387 to get the bolt. I called the Toyota national help line and they confirmed verbally that the last time they came across this problem the problem was solved by the purchase of a complete assembled caliper. The bolt is a 10mm x 1. 25 x 90mm with a hardness stamp of "9".

I have brought my 2000 Toyota Tundra up for a brake inspection repeatedly since Nov 03 for vibrations when brakes were applied. Since November 2003 is when all of this vibration started. I had my rotors turned in Nov 03 after 4,718 miles for vibration when brakes were applied, pads replaced and rotors turned after I felt vibrations when brakes were applied in Mar 04 after 5,345 miles, July 04 3,961 more miles I turned my car in once again for vibration when brakes were applied service manager 1 told me my front brake pads were worn and rotors need turning. Dec 04 I brought my truck in again after 5,055 more miles for vibration when brakes were applied. The rear brake shoes were replaced and drums turned. After a few weeks this problem came back again and each time it costs me hundreds of dollars and I keep having the repeat problem. On Feb 16 06 I called to schedule a check of my brakes. I asked the service manager why do I keep having this vibration since I've owned the car? service manager 2 responded, " there was an upgrade to the defective front brake calipers in September 03, do you have an extended warranty?" I told him I did have an extended warranty when I brought my vehicle in repeatedly and your company didn't fix the problem, only the symptom. A service manager said, "it would have been covered if you had an extended warranty. " I immediately asked to speak with the store manager and he just left for the day. I schedule an appointment with the head manager. The head manager denied the upgrade in the beginning of our conversation but later change his mind after speaking with service manager. My braking system on my 2000 Toyota Tundra is less than adequate. My front end of my vehicle shakes violently when brakes are applied, my exterior mirrors steering wheel, occupants in vehicle shake as well as the contents which may be on the seats. It is very difficult to stop at speeds over 50 mph.

On 9/17/05 I was inform by Toyota dealer that my, 2000 Toyota model Tundra, pickup had a major modification to the brake system by Toyota company . Howerver, since the truck is out warranty, I would have to pay for labor and parts to replace the upgrade parts. The upgrade brake parts consists of thicker rotors, larger calipers and wide brake pads. Since these upgrade indicates that current part are inadequate to do the job of stopping this vehicle under all normal driving conditions, I call the Toyota customer relation office and they agreed the my brakes had been upgraded. They also said, that since the vehicle is out of warranty , I would pay for the labor cost ?and $ 1600 for parts. Based on this information, this is not a question of out warranty, rather it is a question regarding auto safety, and therefore I need your help ASAP. Vehicle VIN # 5tbrt3412ys045509 - bought Jan. 2000- hendrickson Toyota loc. 5201 sample rd coconut creek fla. 33073.

My 2001 Tundra truck has only 80,000 miles and for the second time the calipers and braking system are having to be redone. This starts with severe vibrations in the steering wheel when applying the brakes. If on an incline, the vibration can be so bad it is difficult to hold the steering and stop. You have to release the brake to relieve the vibration and then re-apply quickly. The local Toyota dealership is fixing this problem for the second time and I do not have the old parts. The first time this happened was around 37629 miles in may of 2003, now it has happened again at 80800 miles in September 2005.