Frame Rust problems of the 2002 Toyota Tundra - part 1

Rust problem in frame and rear crossmember.

Tl the contact owns a 2002 Toyota Tundra. The contact stated that the frame was rusted and there was a hole behind the driver's side door. The contact called acton Toyota of littleton (221 great rd, littleton, MA 01460, (978) 263-1500) however, the vehicle was not diagnosed nor repaired. The contact stated the failure was like NHTSA campaign number: 09v444000 (structure). The manufacturer was not contacted. The failure mileage was 220,000.

Frame is severely rusted and called about a previous recall to replace the frame but they told me that I had just missed it and the recall had ended? I told them that I had the truck at the time of the recall but was never notified of the recall. I had received other promotions about new vehicle discounts for Toyota owners, but never about any recall on the truck at all? now the frame is rusted even worse but I have to continue to drive the truck because I cannot afford another vehicle at this time! the other day I pulled into my driveway and noticed the vehicle making a noise and when I looked under the vehicle, the fuel tank strap had rusted and fell apart and the fuel tank was hanging down. I had to take a ratchet strap and strap the fuel tank back up to the frame because I have to have the truck to drive to work. I look now and there is a recall about the corrosion on the fuel tank straps and on the spare tire carrier and such and yet again I was not notified about the recall. Had the fuel tank not fell out on me and then me look on your site to find out about it, I would again not have known there even was a recall until it was too late to do anything about it ! I need to know what can be done about getting Toyota to honor the frame replacement recall on my truck that I was never notified about even though I know that they knew I owned it because of the other mail they had sent me about new vehicle offers for current Toyota owners? any and all help appreciated as I cannot afford to buy another truck having so much money in this one that is eventually going to break in half as I drive it down the road which is not safe for me or anyone else on the road around me. I live in kentucky where is one of the primary areas for salt. Thank you, james travis.

Frame is rusted and won't pass inspection. Have already replaced fender and box.

I purchased this truck used in 2015 and was unaware of any recalls due to frame rust. I have replaced tailpipe, muffler, many brake components due to rust problems. The frame now rusted more and I am being told that it may be unsafe to drive. A mechanic told me about this frame rust recall and I took it to fred anderson Toyota in raleigh,nc. The found that all recall items had been completed by the dealer in boone,nc. I find this hard to believe since the rusting issue is much more severe. I just want a fair evaluation of what can or should be done. Fred anderson Toyota in raleigh did have the truck but not sure how far they took the investigation of rust.

The frame is so rusted there are areas I can put my fist through, the rear shock rusted off the frame while I was driving the truck.

Tl the contact owns a 2002 Toyota Tundra. The contact stated that the frame of the vehicle was rotted out and the mid section of the vehicle had the most rust. The vehicle was taken to an unknown dealer who sprayed the center and mid frames with rust inhibitor; however, the repair failed. The manufacturer was notified and did not assist. The failure mileage was 195,000.

Frame crossmember rusted. Toyota siad it was replaced in 2012 but was never changed.

2002 Toyota Tundra. Consumer writes in regards to frame rust on vehicle.

2002 Toyota Tundra 4wd limited access cab. In Dec 2012 brought truck to burnsville Toyota for recall. They only sprayed rusted inhibitor paint on frame. Brake warning light came on. Brought truck into local independent shop. They said brake line to rear drum brakes shook lose, due to frame rusting/corrosion away from shock absorber mount. They also stated truck is unsafe to drive because frame and crossmember supports are corroded and rusted beyond repair. Called burnsville Toyota and they said, that the recall 3 year warranty had expired and they will do nothing to help. The engine, transmission, and body are still in good shape. Disappointed that Toyota would not offer to help with there designed error in frame.

Purchased the vehicle in February 2017 and was informed by the mechanic that the rear end differential was beginning to leak due to excessive rust. Further inspection of undercarriage do to a noise under vehicle found that the frame and body mount had deteriorated due to rust causing a hole in the body mount causing the cab to flex and bounce on the frame. Vehicle treated by Toyota for earlier recall due to rust of the frame and given a 5yr extended warranty. Body of vehicle is free of rust, frame and differential have excessive rust making the vehicle unsafe to operate.

The contact owns a 2002 Toyota Tundra. The contact stated that the vehicle was taken to an independent mechanic (martinez body shop in belton, missouri) for headlight repairs and the mechanic noticed severe rust on the entire frame. The contact received an unknown recall notification in 2014. The vehicle was taken to milley Toyota in canton, missouri for an evaluation and was advised that the vehicle was perfectly fine and there was no rust. The vehicle was not repaired. The manufacturer was notified of the failure. The approximate failure mileage was 200,000.

The contact owns a 2002 Toyota Tundra. The contact stated that the driver side frame was rusted. The contact notified the local dealer (savannah Toyota located at 11101 aberco, st savannah, GA 31419 912-927-1234), but was not repaired per the recall remedy due to main frame modifications completed on vehicle. The manufacturer was called and informed the contact that the vehicle was not able to be serviced per NHTSA campaign number: 09v444000 (structure) due to the vehicle modifications, and provided case number: 1706013050. The contact had not experienced a failure. The failure mileage was 136,000.

My 02 Toyota Tundra was included in a recall for its frame and crossmembers rusting out and causing an unsafe vehicle. I brought my truck in a couple years ago for the recall. The truck had very low miles for the year under 60k and was taken good care of. The dealer deemed the frame was not rusted through enough to warrant a complete new frame. Instead they sprayed my frame with some rust proof paint. Well that band aide has almost all fallen off and the frame is worse than ever with cross members rusted all the way through. I contacted Toyota hqts and after being bounced around for over an hour was told by a supervisor that I am out of luck because they placed a year warranty on the paint job. Any problems over a year past the warranty work is the consumers problem. Well the paint held for a bit but ultimately did not resolve the underlying rust problem. I was told to follow up with the dealer that had done the warranty work. They inspected the frame and took pictures to send to Toyota, but ultimately said the vehicle was unsafe at this time. I have not gotten any resolution with the issue. My main issue is that they think spraying an undercoat on a rusted frame is going to resolve the rust issue when in fact it was a band aide that has hidden what was manifesting underneath and ultimately destroying a very great vehicle. Toyota has not held up their end in standing behind what it sells and behind resolving major safety problems for its constomers.

Rear frame crossmember rusted through and holes in front frame. In 2011 there was a safety recall on this. Feb,15, 2011 I brought the truck to the Toyota dealer where I bought it. They inspected the frame and sprayed undercoating on it. It was not a sufficient fix. Toyota refuses to fix this problem.

Frame is rusting badly even after Toyota sprayed crc to try to prevent rust.

The frame on my 2002 Toyota Tundra is rusting and has holes completely thru the frame. The truck has always been registered and licensed since new and my problem is never receiving a recall notice. When I learned from a friend that Tundra frame had been replaced, I called Toyota for my frame replacement. Toyota said the recall expired and refused to make the repair. Other that the frame, the truck is in excellent condition because it has been well maintained. It is sad to have an excellent truck setting on a frame that is rusting away. How can Toyota sell a defective truck and identify it as unsafe, fail to contact the owner and then refuse to repair the truck saying the owner missed the deadline. Toyota could have contacted me but I never received any notification. I asked if Toyota could offer any credit on a replacement, even some consideration on a new Tundra and Toyota refused to make any effort to assist me. I currently own four Toyotas. Buyers beware!.

Notified of safety recall on vehicle for rust on frame that will cause structural failure that can lead to loss of control of the vehicle. Took vehicle to Toyota dealer to be repaired. Was told the repair was made. Informed by inspection service center the repair was not effective 8/10/2012, notified Toyota customer care 8/11/2016 of the problem they opened case #1608102651. I contacted them again 8/12/2016 and was informed by the case manager Toyota would not inspect or repair the vehicle. She indicated the recall was listed as limited service and not a safety recall. She indicated this was an on-going issue and several recalls had lapsed for this same problem. Because the recall had expired Toyota was no longer responsible for the defect. They only rust on the vehicle is on the defective frame. A recall repair that does not fix the problem is useless.

The contact owns a 2002 Toyota Tundra. The contact had the vehicle inspected by the dealer and was informed that there was severe frame rust. The vehicle received an undercoating; however, it failed to eliminate further frame rust. The contact was concerned that the vehicle could fracture while driving and caused severe injuries. The manufacturer was notified of the failure. The manufacturer was notified and did not assist. The approximate failure mileage was 74,298.

I found portions of the frame rusted thru and could not mount step bars. I mentioned this earlier in a report. I also just found my spare tire missing and found the bracket holding it had rusted and the tire was lost while driving. When and where is unknown. Toyota examined the truck 2 years ago for a recall for rust issues and said everything was ok. The tire loss is irritating and dangerous to other drivers.

The contact owns a 2002 Toyota Tundra. While the vehicle was being serviced for an unrelated issue, the contact was informed that the frame was rusted. The vehicle was not diagnosed or repaired. The manufacturer was notified of the failure and stated that the vehicle was previously repaired under NHTSA campaign number: 09v444000 (structure). The contact mentioned that the dealer sprayed corrosion protection instead of replacing the frame. The contact felt that the recall remedy failed to repair the vehicle. The failure mileage was 199,000.

Tl the contact owns a 2002 Toyota Tundra. The contact stated that the vehicle's frame was rusted. The vehicle was taken to lee Toyota (115 main st, topsham, me 04086, (207) 729-3358) and the contact was referred to the manufacturer. The manufacturer stated that they could not assist. The vehicle was taken to an unknown facility five years ago for an unknown recall repair related to the failure. The vehicle was treated with an undercoating for the frame to prevent rusting; however, the failure worsened. Lee Toyota also stated that they could not repair the vehicle, but would help refer the contact to an independent mechanic who could help weld the frame. The failure mileage was 90,000.

The contact owns a 2002 Toyota Tundra. Upon taking the vehicle to an independent repair shop for routine maintenance, it was diagnosed that the frame had extensive rust, corrosion, and could fracture. The frame needed to be replaced. The independent mechanic recommended that the vehicle be taken to a dealer. The dealer indicated that a manufacturer recall had been completed in 2012 for the frame of the vehicle, but the contact was unable to confirm if the frame was replaced from the recall repair. The manufacturer also indicated that a recall repair was performed in 2012 and provided no solution. The failure mileage was not available.

Tl the contact owns a 2002 Toyota Tundra. The contact received a recall notice for NHTSA campaign number: 09v444000 (structure). The vehicle was taken to motor world (150 motorworld dr, wilkes-barre, PA 18702) where an anti-corrosive spray was applied to the frame. The frame became rusted a few years later and the vehicle was taken to an independent mechanic. The frame was sprayed again. A few years later, the brake lines had to be replaced due to the corrosion. The vehicle was not repaired. The manufacturer was made aware of the failures. The approximate failure mileage was 105,000.

Severe frame rust causing rusting on brake lines, rusting and hole in the gas tank, steering rack, and rear axle is almost rusted threw. The frame rust is very severe and at this point I am sure it is a safety concern.

The contact owns a 2002 Toyota Tundra. The contact stated that the vehicle was repaired under NHTSA campaign number: 09v444000 (structure) and after the repair, the corrosion protection undercoating that was supposed to remedy the failure peeled off and allowed the frame to rust. The manufacturer was made aware of the failure. The vehicle was not repaired. The approximate failure mileage was 67,000.

Tl-the contact owns a 2002 Toyota Tundra. The contact stated that while parking the vehicle, the parking brake did not engage. The contact observed that there was a fuel leak coming from under the vehicle and when the contact investigated the leak he noticed that the frame was severely rusted. The vehicle was taken to a dealer where it was confirmed that the frame was severely rusted and needed to be repair. The vehicle was repaired under NHTSA campaign number: 09v444000 (structure) however, the failure recurred. Approximately two and a half years later, the contact observed that the frame fractured. The vehicle was not taken to a dealer or diagnosed. The manufacturer was made aware of the failure. The failure mileage was approximately 218,572. Sg.

The contact owns a 2002 Toyota Tundra. The contact stated that the rear frame mounts were rusted and the rear cab of the vehicle was no longer connected properly. The contact took the vehicle to the dealer for repairs under NHTSA recall campaign id number: 09v444000 (structure: frame and memebers: underbody shields), but was advised that the frame mounts were not included in the recall and would have to be repaired at the owner's expense. The failure mileage was 162,052.

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! !.

2002 Toyota Tundra recalled for frame rust issues. Took nearly 5 months for repairs, even with multiple calls to dealer and corporate. Vehicle needed further repairs when returned for broken right front stabilizer bar. Then failed sticker inspection because of dry rot in tires presumably from sitting so long? 1) NHTSA needs to set a reasonable time frame for vehicles to be repaired once recalled. Five months is unacceptable. (2) NHTSA should review whether commingled old rusty 're-usable' parts with a new solid frame isn't in fact creating another issue causing the older parts to fail (there are many reports by bloggers of other things breaking or needing repair post the frame replacement . I personally feel less safe post recall than before (3) NHTSA should be doing post recall follow ups to ensure that Toyota is properly repairing recalled vehicles, especially Toyota's given their recent history. There are reports out there that things like tow hitches are not being replaced because they were 'after market' and in my case, the side steps were simply thrown in the back of the truck because they were too rusty to re-install. They also did not replace front and rear shocks and struts which have to have been compromised by the other rust issue? and (4) Toyota has some severe customer service issues that it needs to address.

My 2002 Tundra and my sisters 2001 Tundra have been recalled twice for rust issues, the first was for gas tank and straps, the second for frame rust. We brought our trucks to herb chambers in auburn MA. For the second time we were told they were fine. Exception was they wanted me to bring my 2002 back because they were "replacing gas tank straps in all recalls as a precaution. " the problem with this is that they told my sister no such thing. Our vehicles are only 8 years old, both gas fill doors rusted shut and we had to break them open to get gas and then replace the locks, my battery housing rusted and I almost lost my battery. Our runners are rusting, the side of my truck is rusting, we both find rust lines on the road or in the garage along the sides of our trucks. A bracket rusted and severed my brake line when I took a turn, my sisters power steering line was severed by a rusted part. Yet our cars are "fine". I was also told that "with the tacoma's we looked for perforations with a hammer and a pick like tool but with the Tundra we will visually inspect for perforations so you won't have to wait long. " my issue is why do I now need gas tank straps? perhaps this will help if any future issues arise. Plain and simply I think that Toyota is not being up front and that is dangerous. Thank you.

I have a 2002 Toyota Tundra that is leaking gas. Initially I noticed a fuel smell when I walked by the truck which progressed to seeing fuel on the ground. If I put too much gas in the truck, over 1/2 tank, you can see the fuel leaking through the 4x4 fuel tank protective cover. I had the truck put on a lift and was told that fuel was leaking from the seam of the tank. I recently took my truck to Toyota in response to the recall re:excessive frame rust and my truck passed that inspection. I have less than 51,000 miles on this truck and I am afraid to drive it on the highway. I have lived in MA for 22 years and have never had a fuel tank problem. On 04/06/10 I took my truck to a required yearly inspection. My check engine light was on and the garage told me that my vehicle had failed the emissions test. I have been following other owners reports online and have noticed that more people are reporting leaking fuel tanks. Extensive research indicates that aftermarket gas tanks are not available for this model/year so I must have Toyota either do the work, or minimally, get the part from them. Based on their recent reputation, I am not thrilled about taking my truck back to them. I have 60 days from the failure date to get it repaired and reinspected to avoid losing my registration! I need this truck to be safe for me and all the other drivers that I encounter. Can you please look into this safety concern?.

My 2002 Toyota Tundra truck is not drivable at this time. The truck was brought to Toyota dealership after a local mechanic found fluid leaking from rear differential due to rust/rot. During the dealers inspection, they also noted a gas smell and suspect that the gas tank or gas lines are leaking also. The dealer did a frame inspection and while the whole frame is excessively rusted, the frame passed the recall test because it had not been perforated yet. The dealer did not want to even remove the differential plug because the whole unit was so rusty. I have been under the truck and personally seen the excessive rust on the frame, fuel system, and suspension components. Amazingly, the body panels have little or no rust and in very good condition. During previous dealer visits we were verbally told that the rust was normal. The repair estimate for gas tank/lines and new differential housing, etc. Was approximately $7000. I purchased this truck new and have always done all required maintenance and was planning on having the truck for a long time. It currently has 89,101 miles on it. The excessive rust is not normal and I feel that the frame and some associated components are defective. I feel that due to the nature of these defects that the vehicle is unsafe to drive and I'm guessing that it would be difficult to sell and if I did, it would be at a greatly reduced value. I purchased a Toyota truck because of their reputation for building long lasting, high quality vehicles. I feel that in light of these defects that they misrepresented their product.

Considerable rust on frame of 2002 Tundra sr5 4x4. The frame actually has holes caused by rust on one of the main support structures on the driver side.

Excessive frame rust and safety issue around steering rack mounting and corrosion to steering rack itself.