Body problems of the 2002 Toyota Tundra - part 1

Excessive frame corrosion and corrosion holes involving even rear subframe.

Frame needs replacement.

I was doing maintenance on front and lifted splash guard for access to bolt. On top of the frame, near the firewall, was severe rust. It looks as if the frame could crack at any time. If this happened in highway speed or in traffic, severe risk of injuries. These are known to have issues in salt states (had recalls) and I thought I checked it pretty good before buying. I think this may be from the air conditioning drain system.

First the gas tank let loose and fell half way off. Result was a new gas tank installed. Then part of the frame rusted from the cab. This resulted in having to have it welded. Have had several service repair lights come on that resulted in more fixes. Today just about does it. The spare tire fell to the road because rust ate through what was holding it up. I have all the papers that show the repairs and what it has cost me. I have not done anything yet about spare tire. I have had the truck since 2013 and it has less then 94k miles on it. It had 35 when I bought it and I knew nothing about the rust problem recall. I certainly believe I should have a new frame or some kind of compensation. Over the years I have talked to several dealers that got me no where. I guess this is my last shot.

The frame on the truck is rusted out with holes through it and the metal is rusted out along the entire frame. The truck vibrates when driving and when inspected by the dealer, kari Toyota, they advised it is unsafe to drive as the frame could break entirely and cause an accident. Report is attached. Toyota was contacted on several occasions by kari Toyota and myself in may and June of 2021. I had the vehicle in for repair of the frame rust issue on June 15, 2012 but clearly the work was not done properly as the rust issue continued until the vehicle is now undriveable. The vehicle has only 106,681 miles which is low for a typical Toyota vehicle. Toyota refuses to repair the vehicle even though I had followed up on my end by bringing it in for the recall repair. I requested a letter from Toyota explaining why they won't cover the repairs and they refused to send one.

Tl-the contact owns a 2002 Toyota Tundra. The contact stated that the vehicle was taken to an independent mechanic for maintenence and was informed that the cross members on both sides in the rear were severelly corroded along with the frame and needed replacement. The vehicle was not taken to the dealer for a diagnostic. The manufacturer was not notified of the failure. The vehicle was not repaired. The approximate failure mileage was 86,. 000. Bp.

2002 Toyota Tundra sr5 frame was sprayed with undercoating per recall when it should have been replaced. Now frame has holes 1" wide 4" long behind front tires on both sides. Body still looks new. I see trucks for sale that are rusted out beyond repair but have new frames.

The chassis of the truck is very damaged by rust, in some parts it even has holes, so I do not know if it is very safe to handle it. I bought it at a car dealer a few weeks ago, I thought it was just a bit of rust . . . But when I checked it out better I now find that the rust really harms the structure, another problem . . . It gives off a strong smell of gasoline. . .

Frame of truck was totally rusted out and vehicle was considered "non-drivable", by Toyota dealership. Toyota dealership "checked" the frame in 2011 and said it was "fine" and we have only driven the truck 40,000 miles since. They said to salvage the truck but it only has 127,000 miles on it!!!! case #1905282857.

Tl- the contact owns a 2002 Toyota Tundra. The contact stated that during routine maintenance harr Toyota 100 gold star blvd, worcester, MA 01606 (508) 471-2530 informed them that the entire frame was corroded. No warning lights illuminated. The vehicle had not been repaired. The manufacturer was made aware of the failure but not able to assist. The failure mileage was 157,000. Nd.

During an oil change the mechanic noticed the frame just in front of the leaf spring bracket was severely rusted through making it dangerous to drive. We did have Toyota supposedly address a potential rust situation in 2012. However, this damage should not have occurred if this was supposedly addressed. We have contacted Toyota and they have told us that there is no assistance that they can provide at this time. We are concerned that there are potentially many other vehicles with the same issue and are totally unaware of their dangerous situation.

The rust corrosion is so bad that the spare tire feel off hitting the leaf spring support bracket and completely caused the bumper to fall off the truck. The spare tire rolled into oncoming traffic and almost caused an accident. The corrosion is evident all over the chassis and other parts. This happened while I was driving and pulling a landscape trailor on route 173 in new jersey.

Tl-the contact owns a 2002 Toyota Tundra. The contact stated while driving at approximately 10mph the contact heard a noise under the vehicle and the contact noticed that the separated and was on the street. The contact was able to retrieve the spare tire. The contact inspected the vehicle and found that the spare tire holder was severely corroded with a hole and the tire brackets were also corroded the brackets stick to the tire rim causing the tire to fall. The contact also found that the vehicle under frame was also corroded. The vehicle was not taken to a dealership to have an inspection performed. The vehicle was not repaired. The manufacturer was notified. The VIN was not available. The failure mileage was 126,000. Li.

Tl- the contact owns a 2002 Toyota Tundra. The contact stated that while operating the vehicle a clunking noise was present coming from under the vehicle. The vehicle was taken to the local dealer sansone Toyota(90 us-1, avenal NJ. ) who examined the vehicle and discovered that the subframe was severely damaged do to rust and corrosion. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was 240,000. Jft.

The remedy applied to my 2002 Toyota Tundra for safety recall 09v444000 has proven to be ineffective. I purchased the truck used from the Toyota dealership where the safety recall remedy had been performed. The frame cross-member which supports the fuel tank - a component called out in Toyota documents related to 09v444000 - has separated from the frame on both sides. (see attached photos) this condition was discovered during my recent state inspection. I was told that it is dangerous to operate the vehicle in this condition until the cross-member which supports the fuel tank can be repaired or replaced. Since recall 09v444000 was originally initiated to fix this very problem, I believe my vehicle should still qualify for this repair because the fix applied was a band-aid repair that did not address the original fault. Your database currently shows there are no longer any open recalls on my VIN, but the original flaw has progressed to the point where the vehicle (which is otherwise in excellent condition) is unsafe to operate on public roadway. Is Toyota obligated to address this issue, or was their temporary fix (the application of rust-proofing) enough to absolve them of any responsibility from that date onward?.

Tl the contact owns a 2002 Toyota Tundra. The contact stated that there was extensive rust and corrosion pertaining to the frame. The vehicle was not diagnosed or repaired. The vehicle was not included in NHTSA campaign numbers: 09v444000 (structure) and 05v225000 (suspension). The contact was uncertain if the failures were related to the recall campaigns. The vehicle was not repaired. The manufacturer was notified of the failures and indicated that the buy back option and frame replacement extended campaign ended in 2012 and there was no remedy. The failure mileage was not available.

In 2012, my frame was recalled for rust. Toyota applied a corrosion resistant spray compound. It did not work. Now I have rust holes coming from the inside out.

The contact owns a 2002 Toyota Tundra. While the vehicle was stationary, the contact noticed that the main frame of the vehicle was severely rusted with holes. While changing the brakes, a large piece of the frame fell onto the ground. A dealer was not contacted about the failure. The manufacturer was made aware of the issue and stated that the frame replacement warranty expired on June 1, 2017, but the VIN was not included. In addition, the manufacturer provided the contact with case number: 1708210712. The failure mileage was approximately 300,000.

Truck inspected by Toyota for corrosion and treated with chemical as part of the recall notice. At this time I had no concerns with condition of the frame for safety concerns. My truck was treated 10/24/16 by Toyota and during a routine exhaust fix mechanic showed me areas of concern on rear of the frame. The dealership that performed the treatment looked at the frame again and stated they diidnt want to touch or check the areas of concern a incase they made holes in the frame. I opened a case with Toyota and indeed got a second opinion from another Toyota dealership whom deemed my vehicle unsafe to drive due to frame corrosion in the areas that were treated , now this was only 3 months after Toyota treated the frame. I was given a case manager at Toyota for special circumstances as he quoted, and 2 days later was told nothing could be done. I also have a gas leak which has materialized around the rotted crossmember . Overall in 3 months I now have perorations and delamination of the rear frame and a junk truck.

The front frame on the passenger side has a large rust hole completely through it, by the sway arm bracket, and that bracket itself is loose and hanging. The vehicle has 139,000 miles on it.

The contact owns a 2002 Toyota Tundra. The contact stated that the vehicle could not pass inspection due to a rotted frame. The vehicle was repaired per NHTSA campaign number: 09v444000 (structure) four years ago; however, the failure recurred. The manufacturer was notified. The vehicle was not repaired. The VIN was unknown. The approximate failure mileage was 204,000.

Had to replace all 4 oxygen sensors. The front two were faulty before 50000 miles and less than 7 years old. The rear differential cover is rotting and leaking fluid. The only way to repair it is to weld over the hole.

There is excessive rust across the entire rear end of the truck. The rear axle casing has started to deteriorate to the point that differential fluid is leaking from the casing. I have already had to have the frame, spare tire and fuel tank replaced due to excessive rust.

The contact owns a 2002 Toyota Tundra. The contact noticed severe rust on the front cross members and the frame. The dealer informed the contact that the recall expired and the repair cost would not be covered by the manufacturer. The manufacturer was notified of the failure. The vehicle was not repaired. The approximate failure mileage was 94,000.

The contact owns a 2002 Toyota Tundra. Whle the vehicle was being inspected, it was discovered that the tire bracket and the spare tire separated from the vehicle due to excessive corrosion. The contact indicated that the vehicle was previously inspected per NHTSA campaign number: 09v444000 (structure); however, the failure recurred. The manufacturer was not notified of the failure. The failure mileage was 231,000.

The contact owns a 2002 Toyota Tundra. While the vehicle was at a dealer for service, the technician diagnosed that the subframe was corroded and needed to be replaced. The vehicle was not repaired. The vehicle was previously taken to the dealer per NHTSA campaign number: 09v444000 (structure); however, the dealer refused to perform the recall repair stating that the repair compound was not being sent by the manufacturer. The manufacturer was notified of the failure and refused to perform the recall repair, stating that they were no performing the recall repair. The failure. The VIN was invalid. The failure mileage was unknown.

We have a serious rust issue with our 2002 Toyota Tundra. Toyota replaced a frame but reattached all the already rusted pieces back onto the new frame. The break line has rusted through on several occasions. We have gone through a red light & stop sign. No was hurt, we were lucky but this truck is a death trap. We have hit the side of the garage trying to get it out of gear because everything is so rusted. We have contacted Toyota & have been told it's a maintenance issue not a defect. This truck 100% a defect! it is a pile of metal sitting in our driveway because I refuse to put my family in it. It us irresponsible to drive this vehicles, so in our & the publics best interest it sits in our driveway.

Tl-the contact owns a 2002 Toyota Tundra. The contact stated that the front end of the frame of the vehicle is rusted and has a hole in it. The vehicle was not repaired. The manufacturer was not made aware of the issue. The failure mileage was 163,000. Ad.

Tl- the contact owns a 2002 Toyota Tundra. The contact stated that the vehicle was taken to an independent mechanic for a state inspection and it was discovered that the frame was severely corroded. The contact mentioned that a notice from the manufacturer was received to fixed the corrosion of the frame for free. The vehicle was taken to the dealer where it was diagnosed that the rear brake lines and the frame were severely corroded. The contact mentioned that a corrosion protection compound was used by the dealer but the failure recurred. The VIN was not included in the NHTSA campaign number: 09v444000(structure). The manufacturer was notified of the failure. The failure mileage was 65,000. Jo.

Tl-the contact owns a 2002 Toyota Tundra. The contact stated that while driving at various speeds, a loud abnormal rattling noise emitted from the vehicle. The vehicle was taken to the dealer. The technician diagnosed that the frame had cracked due to corrosion and needed to be replaced. The contact mentioned that the vehicle had been previously repaired and treated under NHTSA campaign number: 09v444000 (structure). The manufacturer was made aware of the failure and refused to provide any assistance. The vehicle was not repaired. The failure mileage was 120,000. Pm.

Truck needed sensor replaced for safety inspection sticker (check engine light on). Mechanic found frame underneath to be so rusted he was not comfortable working on the truck. I took the truck to local dealer and they agreed the truck is rusted to point of being unsafe. They took pictures to send corporate for frame replacement approval. Request was denied. I then called Toyota customer service several times before they agreed to assign a case number. I was eventually told that although truck is unsafe, there is nothing they will do since campaign is closed. I had the truck sprayed as initial recall stated. I received no other recall or requested service information from Toyota. I now have a truck with low mileage that will not pass inspection and is unsafe to drive and Toyota will do nothing to make sure their customers are safe or care about the safety of other drivers on the road should parts of my frame start falling off while driving. I find this practice very neglectful especially for a large corporation. I have seen that many others are in the same position with their Tundra. I would like to know what can be done to rectify this safety issue. Toyota should be made accountable.

The contact owns a 2002 Toyota Tundra. The contact stated that while having repairs performed, the independent mechanic discovered that the frame reel that connects the leaf springs had completely rusted. The vehicle was not repaired. The manufacturer was made aware of the failure. The approximate failure mileage was 140,000.

When driving over unequal pavement on road, felt and heard noise at rear of vehicle. Saw wheel tumbling down road behind vehicle. Stopped vehicle and noticed that it was spare tire from vehicle. Placed spare tire in bed of truck and when I got home, noticed that the bracket/plate that was securing the spare tire to the underside of the bed had separated from the cable that was holding it in place. The bracket/plate was so corroded/rusted that when the truck hit the bump, the weight of the spare wheel caused it to collapse and allowed the spare tire to fall onto the road.

Tl- the contact owns a 2002 Toyota Tundra. The contact stated that while driving various speeds, the front passenger's side tire became detached unexpectedly from the vehicle. There was a loss of steering control and the vehicle began to skid 35-40 feet before proceeding to stop. The vehicle then collapsed to the ground. The vehicle was towed to an independent mechanic and an authorized dealer, in which both informed the contact that the brake lines and the frame was corroded. In addition, the front passenger's side ball joint was defective. The contact referenced NHTSA campaign id numbers: 09v444000 (structure) and 05v225000 (suspension) however, the vehicle was not included in either. The manufacturer was notified of the failure. The approximate failure mileage was 250,000. The VIN was unavailable. Kmj.

Tl - the contact owns a 2002 Toyota Tundra. The contact stated that while driving 65 mph, a loud noise dragging noise was heard. After inspecting the vehicle, the contact noticed that the fuel tank was dragging on the ground. The vehicle was towed to a dealer and diagnosed that the universal joint had become fractured and as result, the drive shaft and fuel tank were dropped. The contact decided to take the vehicle to a second dealer for and the technician stated that the frame was cracked. The manufacturer was made aware of the failure. The vehicle was not repaired. The failure and current mileage was 170,000. Kmj.