Frame Rust problems of the 2004 Toyota Tacoma - part 2

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

36 Frame Rust problem

Failure Date: 09/01/2015

Near terminal frame rot. Excessive rusting of frame. No rust on body.

37 Frame Rust problem

Failure Date: 06/23/2015

Tl-the contact owns a 2004 Toyota Tacoma. The contact stated that after the vehicle was inspected, the technician informed that the frame was rusted and needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was 167,000. Ss.

38 Frame Rust problem

Failure Date: 06/04/2015

The contact owns a 2004 Toyota Tacoma. The contact stated that the frame prematurely rusted. The vehicle was unable to pass an inspection due to the failure. The dealer and the manufacturer were notified of the failure and provided no remedy. The approximate failure mileage was 147,000.

39 Frame Rust problem

Failure Date: 04/04/2015

I was at the local tire shop getting two tires installed and I noticed that the right rear of my vehicle was not level with the left. I asked that they do an alignment to even the vehicle out and they notified me that the frame was severly rusted. I was told that there was a campain recall on thi same issue and my VIN was in range. When I went to the dealership they notified me that there was another part of this recall, that they did not do, so my frame was not covered. I never received any notice of either recall. I sent a email to Toyota and they called back with the same responce "you never did the ani-corrosion part of the recall so you do not qualify". I have heard of countless persons in my area that have just purchased the same age vehicle and had frame rust that got there vehicles repaired. If there is an issue with or without this corrosion spray why are only certain vehicles covered. This spray does not work and this seems like a way to get around repairing vehicles. Not to mention I never received any recall notices and they have no record of what adress the recall was even sent to.

40 Frame Rust problem

Failure Date: 02/05/2015

Tl-the contact owns a 2004 Toyota Tacoma. The contact stated the vehicle was taken to an independent mechanic for an unrelated repair and they discovered that the entire frame had rust corrosion. The vehicle had not been repaired. The manufacturer was notified of the issue. The approximate failure mileage was 56,000. Js.

41 Frame Rust problem

Failure Date: 12/14/2014

Purchased this vehicle in June of 2014. The carfax report only listed a recent recall dealing with the spare tire hanger. The carfax report did not show any other recalls, including the frame treatment, the frame replacement or the truck buy back offered by Toyota. We we completely unaware of the recalls. Two weeks ago, the rear right shock rotted/completely broke away from the severely rusted frame. Toyota says they will do nothing because "we" didnt have it treated. However, we had no knowledge of the recall and had no way of knowing that there was a frame problem because the dealer indicated no issues, the carfax report showed nothing and we have only owned the truck for 6 months. We don't know what to do. Are we stuck with this or can we hold someone accountable for help?.

42 Frame Rust problem

Failure Date: 09/27/2014

I was driving down the road and noticed some unusual rattling. I stopped and upon inspection found that the frame on both sides had cracked all the way through directly above the rear tires. This rendered the vehicle extremely unsafe to drive. I had it towed to a repair shop and they told me that a complete frame replacement needs to be done and that the vehicle is unsafe to drive as is. They said the frame is completely rusted out. I understand the vehicle came out of new york and has high salt concentrations but the rest of the truck is virtually rust free. I can’t believe that a frame rusting completely out is normal in just 10 years. I have contacted Toyota (case number 1409290440) and they are telling me that any recalls pertaining to this have expired. I can’t believe they will not step up and fix what is obviously shoddy craftsmanship. My main concern is this could have caused a serious accident. They stepped up to the plate with the 1995-2000’s that had the exact same issue and obviously was not fixed in the 2001-2004 models. I am very disappointed with Toyota and very concerned for the safely of other Tacoma owners as this seems to be a pretty common issue with these trucks.

43 Frame Rust problem

Failure Date: 04/23/2014

Tl-the contact owns a 2004 Toyota Tacoma. The contact stated the vehicle was taken to an independent mechanic for an unrelated repair and they noticed that the entire frame was rusted. There was a voluntary recall issued by the manufacturer, however the recall expired. The vehicle had not been repaired. The manufacturer was notified of the defect. The approximate failure mileage was 78,000. The VIN was unavailable. Js.

44 Frame Rust problem

Failure Date: 02/19/2014

Called Toyota after PA state inspection was told that the frame was rusting out. Got the run around from Toyota stating that there was a preventative coating recall that my fiancã© didn't have preformed. When I called Toyota they didn't have her information and she owned the truck four years pprior to the call. After they blew me off. She got her first recall notice for the spare tire, took it to Toyota on 1/13/15. They can nt preform the recall saying the frame is rotting to bad and the truck is unsafe. Look at the post on line look at edmunds look on google this is a huge safety and consumer protection issue why wont the government step in and address this or do people need to die first.

45 Frame Rust problem

Failure Date: 11/06/2013

I own a 2004 Toyota Tacoma and have regularly serviced and maintained my truck, which has always been stored in my garage. On November 6th, I went to have my yearly vehicle inspection and was told that the truck failed because of rust in the frame near the gas tank. John, the garage owner, told me about the Toyota recall for the frames, and said he believed my truck was included in the recall. I then called the Toyota dealership where I bought my truck, woburn foreign motors in woburn, MA, and they were unsure about the recall procedure because they thought the recall had expired. The service manager gave me the VIN number and confirmed that the truck was on the recall list. She gave me the phone number to call Toyota corporate. When I spoke with them, they told me that the recall had expired in 2011, and they assigned a case manager, [xxx], who would be the only one that could over-rule the expired recall. He called me a day later, and said Toyota would not take care of it because they had sent me a letter notifying me that I was to take it in so they could do undercoating. I told [xxx] I never received the notice in the mail. Since my profession was pharmacy, I am very detail-oriented, knowing the importance of recording when we dispense prescriptions to customers. I believe that Toyota is at fault for this problem, and they should stand by their product and resolve it. I recently received another recall notice on November 14th, 2013, for a spare tire mount under the truck that may rust and make the tire fall. Toyota asked me to bring in the truck for repair to resolve that issue, but not the frame. Without a replacement frame, I am unable to drive the truck because it is dangerous and cannot pass inspection. Having always maintained my vehicle, the truck engine and cabin are in excellent condition. I would appreciate any help you could provide. Thank you. Information redacted pursuant to the freedom of information act (foia), 5 u. S. C. 552(b)(6).

46 Frame Rust problem

Failure Date: 04/16/2013

Tl- the contact owns a 2004 Toyota Tacoma. The contact stated that the vehicle was taken to an independent mechanic for inspection and they detected that the entire frame exhibited rust. There was a voluntary recall issued by the manufacturer related to the frame; however, the recall expired. The manufacturer was notified of the defect. The vehicle had not been repaired. The approximate failure mileage was 92,000. Mah.

47 Frame Rust problem

Failure Date: 04/01/2013

I purchased a used 2004 Toyota Tacoma 4x4 4 years ago in NY. I moved to MA 2 years ago and took truck to a cape cod Toyota dealer and asked them to change oil and tell me if there were any issues I needed to deal with. To make a long story short they told me about the spare tire rust recall and made the repair. When we picked up the truck they gave it a clean bill of health. They then said "by the way, you have a tiny hole in frame that may need to be taken care of at some point-not urgent. " fast forward 2 years- a garaged truck that only had an additional 7,000 miles. We took it for the MA state inspection and it failed. They said it needed a new muffler. We took it to our local cape cod mechanic who called and said the problem was much bigger- the entire frame is rusted out and it is not safe to drive. We filed a complaint with Toyota corporate and they won't do anything. The dealer called to say come pick it up even though they know it is not safe to drive. How much is a life worth? obviously Toyota doesn't care. Help please!!!.

48 Frame Rust problem

Failure Date: 02/12/2013

The contact owns a 2004 Toyota Tacoma. The contact stated that he heard an abnormal noise from under the vehicle. The vehicle was taken to a mechanic for inspection where they advised that the frame was rusted and the cab mounts were corroded. The vehicle was not repaired. The manufacturer was notified but provided no assistance. The failure mileage was 78,255.

49 Frame Rust problem

Failure Date: 01/01/2013

I just wanted to tell how utterly useless I think this administration is. I wrote in with a complaint on my 2004 Toyota Tacoma which has a rusted frame and too dangerous to drive. There were numerous complaints just like mine and still are all over the internet and you have done absolutely nothing. Toyota refuses to fix my truck and I never received a notice for my truck frame as well as a lot of others. If I had kept driving this truck me or others could have been killed. I have a conscious unlike this office and Toyota. I contacted my senator and asked him how many complaints do you people need to do something. I guess somebody has to die first which is sinful and sad!!!.

50 Frame Rust problem

Failure Date: 05/06/2009

I got a letter from Toyota motors stating that ceryain model years of Tacomas had rust damage to the frame and I was informed to bring it to the dealership where they would perform a rust test on it. Mine is a 2004. They said the rest wasnt bad enough to replace the truck,of course and kept it to spray on a rust preventative on the frame. Within one year the coating they applied began to fall off peel off and obviously didn't work like planned. My sister had a 98 Tacoma with the same issue and you could put your finger through the frame. They bought her truck back at the corporate office at 150% of bluebook value. Thats what should happen now also. Ive paid 20k$ for the vehicle brand new and a major reason was everyone likes the Tacoma and its fairly easy or lets say was easy to resale before all the problems they are having. Now ive gotten another letter saying there is more than one recall and now have problems with the spare tire holder plate possibly rusting and falling off. Its pretty obvious to me and all the customers who have had the problens, that Toyota must be forced into actually replacing the vehicle or pay the 150% book value without arguement. Is anyone going to make this right? I have had 2 mechanics tell me the truck is unsafe and not road worthy. Luckily I have a company vehicle otherwise I would be very challenged. The bumper all the way to the front is totally rusted out and I dont wanna hear lip service saying its due to salt or something I just want a billion dollar company to be responsible for their product. I havent dtiven the truck but 10 times since getting the coating applied and the sad thing is I love the truck and cant drive it. Please help us.

51 Frame Rust problem

Failure Date: 04/01/2009

We own a 2004 Toyota Tacoma. After receiving a letter from Toyota about frame rust, we took our vehicle to the dealer for the requested inspection. The dealer told us that the frame has soft spots and that Toyota recommended replacing the frame. We are seriously concerned about the safety of this vehicle given the fact that the structural integrity of the vehicle has been compromised. However, we question this kind of invasive repair. We want Toyota to buy the truck back given the nature of this safety defect. Toyota has a defined history of defective frames in the Tacoma: they bought back many 1995-2000 Tacomas for the same reason. Since the 2001-2004 Tacomas are experiencing the same defect -- a very serious one -- Toyota needs to take responsibility and properly compensate owners like us by buying them back. We request that the NHTSA do what is necessary to require Toyota to take responsibility in this matter by recalling all affected Tacomas so these vehicles can be taken off the road before injury and death results. Thank you for your attention to this very serious matter. Peter spangenberg.

52 Frame Rust problem

Failure Date: 07/04/2008

Information redacted pursuant to the freedom of information act (foia), 5 u. S. C. 552(b)(6). 2004 Toyota Tacoma [xxx] rusted rear step bumper,rusted inside out,no fault of owner Toyota refuses to replace the bumper to date 02/2010 frame is slowly rusting out also/inspected by dealer/ok for now!.

53 Frame Rust problem

Failure Date: 01/15/2007

Very rusted frame.

54 Frame Rust problem

Failure Date: 01/11/2006

The contact owns a 2004 Toyota Tacoma. The contact stated that there was rust on the frame of the vehicle. The vehicle was taken to the dealer for inspection where they confirmed that the vehicle exhibited a rust issue. The vehicle was not repaired. The manufacturer was notified but did not provide any assistance. The failure mileage was 45,000.


Other Structure related problems of the 2004 Toyota Tacoma


Safety Ratings of Tacoma Cars
Fuel Economy of Tacoma Vehicles
Tacoma Service Bulletins
Tacoma Safety Recalls
Tacoma Defect Investigations