Front Suspension Leaf Spring problems of the 2002 Toyota Tacoma

Hello, I own a 2002 Toyota Tacoma and I brought it to a local Toyota dealership where a service advisor came out to the parking lot, got under the vehicle and noticed that the frame has rusted through (he stuck his hand through the rust hole) near where the leaf springs attach to the frame. It is a known safety issue and Toyota has repaired/replaced many Tacoma¿s due to this safety issue. I did some research, and found out that Toyota knows their frames are unsafe, and have extended the warranty to 15 years from the date of new car delivery. I tried to get mine replaced since its still well within time-frame, but they are stating that the original owner refused a frame inspection/application anticorrosion spray so now they will not honor the unsafe frame. I have vehicle service history showing other recalls (front ball-joint) were done, and other repairs to the car, so its likely that the original dealership did not offer the application anticorrosion spray, otherwise the owner would have had this free service completed (the customer serviced it regularly and kept it in great shape) and the frame would not be unsafe. Original new car delivery date was October of 2002, meaning the 15 year frame recall safety issue is covered until October of 2016 (a year from now). I spoke with Toyota customer service and they are unwilling to do anything about this known safety issue. In any case, since Toyota knows its a safety issue, and its well within the 15 year recall frame time-frame, why should Toyota expect me to just drive around an unsafe vehicle?.

Vehicle has low miles yet the frame has rust holes in it. Toyota won't do anything about it even though it has frame inspections in it's recent service history. The first inspection occurred in 2010, less than 7k miles ago. They indicated to me on the phone that due to an agreement with NHTSA that they could not do anything to help me. They would not take ownership for not inspecting the frame properly. This is a major problem with Tacoma's, tundra's, sequoia's and 4runner's of this vintage in cold climate states. Toyota acknowledged the frames were of poor manufacturing even suing the frame manufacturer, yet some get new frames, others like myself with a low mile truck are told they could do absolutely nothing even though the vehicle was traded in less than 1600 miles ago at a Toyota dealership in PA. Toyota needs to own up to this major safety issue and address it instead of skirting the issue without a proper recall. I have seen videos of Tacoma's which have literally broken in half due to this problem. Never did I think Toyota wouldn't stand behind this potentially fatal flaw in frame manufacturing and corrosion resistance. My frame has a large 1"x6. 5" hole above the right front leaf spring mount - a key attachment point for the rear suspension.

After having my 2002 Toyota Tacoma off the road and garaged for the past 3 years, I was getting the truck ready to be driven on the road again. I am the original owner. I took the truck off the road because my job was eliminated in October 2010. After changing the oil last weekend in my garage I noticed an abnormal amount of rust on the frame. In fact, so much rust that the rubber body mount block on top of the rear leaf spring snapped off in my hand. The leaf springs, brake lines, and front suspension and frame are all in question regarding vehicle safety. I immediately did research online to check out what I thought was abnormal amounts of rust on the frame and to see if anyone else had experienced this too. I was shocked at what I found. A huge safety issue with Toyota Tacoma rusted frames. I come to find out online that Toyota has a history of rusted frames, breaking frames, unsafe frames, and a recall currently for a rear spare tire mount issue due to rust. I also found out Toyota was replacing frames on my model. I called my dealership to set up an appointment to have this truck inspected for pennsylvania state requirements and to have the rust checked. They told me my vehicle was not valid for the rust inspection and the frame replacement because the program expired, I was told to call Toyota. I was never notified by Toyota or my dealer there was an issue, not by mail, phone calls or certified mail. I had the truck parked in my garage for three years so it wasn't even on the road during this time. Several phone calls later to Toyota and they refuse to replace my frame under the customer care program citing I did not have the undercoating applied by December of 2012. Toyota customer service said I could weld reinforcement plates to my frame myself or find a junkyard frame. Really Toyota?.