Brake Disc Caliper problems of the 2002 Toyota Tundra

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.

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.

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! !.

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.

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.

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.

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...

This compliant is applicable to Toyota Tundra trucks ~2000 to 2003 models. A very strong brake vibration felt through-out the vehicle coming down mountain passes (I live in colorado). Even with the appropriate down-shifting the brake vibration is frightening causing the driver to wonder if the vehicle will be able to be slowed after a while. This is a known defect to Toyota motor corp and is addressed in the Toyota service bulletin br004-02 and is only addressed upon complaint by the customer and then again only at no charge if the vehicle is within the warranty limitations. The fix is a design change in the form of repalcement of the front caliper assembly and the front rotors. The rear drums might also have to be replaced with drums of greater mass and rigidity, according to the TSB br004-02.

1. Excessive break vibration during stoping. Thought to at first related to tire balance. 2. Front brake rotors warped from heat buildup and improper ventilation. 3. Contacted local Toyota service department. Advised of (Toyota TSB #br004-02 brake upgrade) authorizing replacement dust shields, front rotors, calipers,pads,rear drums,and pads. Toyota refuses to repair with mileage being 41,000 as truck is not in warrenty. Toyota would like to repair for $1803. 25. Toyota would not comment on why I was not advised of this problem before warrenty expired. As of now, have contacted Toyota southeast and issue not resolved. Tundra will now have to be repaired out- o-f pocket, as break failure is imminent, and safety is compromised. Independent mechanic suggest replacing rotors with performace cooling disc and ceramic pads to minimize warping.

Vehicle has excessive vibration/shaking when braking, especially downhill, and most notably at speeds between 40-50 mph. Repair attempts have been made at 20,341 miles and 24,312 miles replacing calipers, rotors and drums, as well as attempts at resurfacing badly warped rotors/drums. Condition still exists at current mileage of 28,128 miles. Fear that this is a dangerous condition that will result in loss of handling, control, traction or may lead to an accident if brakes fail to stop the vehicle. As this also does not appear to be an isolated case, this condition is likely to affect vehicle reputation and (re-sale) value as well.

(1) on 7/30/03 at 5796 miles, only 10 months after purchasing a 2002 Toyota Tundra (9/27/2002), I experienced a violent vibration during light braking at speeds of 45-60 mph. 2) concerned for my and other motorists' safety, I took it in to the kirkland Toyota dealership. (3) kirkland Toyota completed the front brakes campaign and replaced the following under op code br2005: calipers, brake pads, wheel bearings, backing plate, turn rotors, and tubes. They also bled the brakes and torqued the wheels. (1) on 8/13/04, at 10494 miles, I noticed that the violent vibration had returned. (2) concerned for my and other motorists' safety, I took it in to the kirkland Toyota dealership again. (3) kirkland Toyota test drove the vehicle and found the TSB on rear brake vibration, op code 472151 combo code a. The service dept. Relaced both rear drums. (1) the following day, 8/14/04 I test drove the vehicle and discovered that the violent vibration during light braking had increased, now occurring on both grades and flat surfaces. (2) my next step is to contact the dealership again, but I am not encouraged that a solution will be found.

Recurring brake vibration problems with 2002 Toyota Tundra access cab v8. Calipers and rotors were replaced under a service bulletin, but problem comes back.

Manufacturer refuses to service faulty brake system while under warranty - 2002 Toyota Tundra 2/03-I took my 2002 Toyota Tundra to a dealership in scottsdale, az (right Toyota) with concern over brake pulsation. The mileage on my vehicle was 32,000 miles. The dealer informed me that my truck was due for a 30,000 mile service interval and checking brakes was normal procedure. I received an invoice noting my front brakes were 90% worn & rear brakes were 40% worn. The dealership offered to replace the front pads for $400. I declined and had my brakes serviced elsewhere 1/13/04-I took my truck to a second dealership in phoenix, az (camelback Toyota) for the 60,000 mile service interval. The dealer performed the service and in the process of checking the brakes noted the entire brake system should have been replaced due to two technical service bulletins (#br004-02; #br003-02) the condition of the rotors and drums were warped, with excessive wear. The dealer wanted to replace the brake system. They said that the required service should have been performed under warranty with the tsbs. The mileage limit on those tsbs was 3 years or 36,000 miles. Since I was over the mileage requirement, yet had originally brought my truck in for this exact problem prior to 36,000 miles Toyota offered to cover the parts if I paid the $1,100. 00 in labor. I refused because this problem was alerted to Toyota prior to 36,000 and was mis diagnosed as worn pads I called Toyotas corporate services number at 800-331-4331 with all the details of this case. They have refused assistance. Toyotas internal reference number for this is 200401090758. I have documentation (the 30kmile service invoice) that notes I had brake issues prior to the expiration of the TSB warranty covering the brakes. It has been provided to camelback Toyota, and the factory is aware of the issue, yet they still refuse to honor their own policy for replacing a brake system that is unsafe.

Vehicle vibrates when brakes are applied at freeway speeds. I have taken the vehicle to two dealerships, six different times and problem is still there. The following has been replaced several times. Rotors, calipers, bearings, rear drums and brake pads. The rotors have been replaced twice because they warped in two weeks time. Last dealer told me that their tech. Could not find what the problem was and that someone from Toyota would have to come test drive with me. I am concerned that the vibration will become a safety issue.

Improper front brake caliper size, which causes warping of the front brake disc ,and subsequent serious steering wheel vibration of my 2002 Toyota Tundra. Toyota is declining to issue an official recall of the defective brake components, and dealers have been uncooperative in fixing this problem. I hope no one has to be injured for Toyota to take this seriously.

Vehicle purchased 4/22/2002. All of the pulsating, vibration while braking downhill (as described by so many in the preceding 21 complaints under "component" service brakes. Hydraulic), occurred 8/20. 2002-warranty week. , 5/1, 2003-more warranty work, finally on 1/5/2006 went to napa auto repair and finally paid for a sensible analysis of the problem and so far a good braking experience. Current mileage is 35,800 miles!! I hope that somewhere in this complaint I will be able to share the reasoned analysis by napa regarding unsized front pads before I run out of space: larger pads for sequoia installed. Sequoia has 4 wheel disc brakes-curb wt. 5280. Tundra-curb wt. 4518. Tundra rear brakes-drum. Smaller pads in front than sequoia. Initial problems seemingly develop when rear drum shoes wear down unevenly thereby putting more wear on small front discs. No "failures" or "deaths or "injuries" to report--(sorry) but only because most of us slow down before the inevitable occurs! warranty work on the two described occasions is listed as:"f. Disc 1-sd gnd comb:opposite side rear brake drum (one side) r&r opposite side" in may, 2003 at 11,611 mi. : "replaced calipers per TSB, resurfaced front rotors, rear brake drum r&r, strut set (2) parking brake. Replaced rear brake drums". I hope that my experience will generate some manufacturer recognition and admission to their problem. Thank you, I. L. Turner.