Body problems of the 2003 Toyota Tundra - part 1

Nhtsa campaign 09v444000 for 2000-2003 Toyota Tundra to address severe corrosion on the rear frame cross-member section or rear brake lining proportion valve. Vehicle was apparently treated with crc in 2010, but vehicle continued to rust severely in the specified recall zone, even after Toyota safety recall 90m had been completed on the vehicle. The crc applied to the rear frame cross-member of the frame as specified did not inhibit further corrosion of the rear frame cross member, if anything it accelerated the corrosion. Thousands of 2000-2003 Toyota Tundras titled in the specified severe cold weather states still remain in use, and pose a threat to the overall safety of drivers. The Toyota 90m safety recall did not adequately inhibit the corrosion of the rear frame section, rendering the vehicle unserviceable & unable to align, and leaving gas tanks, rear suspension, rear drive train, and spare tire parts susceptible to falling off of the vehicle and causing an accident- posing a risk of severe injury/death to road users. I am asking that the NHTSA please look into reissuing the NHTSA campaign 09v444000 to have all 2000-2003 Toyota Tundras still registered for road use in severe cold weather states be inspected by a certified Toyota dealership for repairs, frame replacement, or vehicle buybacks to prevent unnecessary accidents due to a manufacturer defect that was never rectified properly.

The frame was undercoated incorrectly and is actively falling apart. Super unsafe to drive. Very clearly was not undercoated correctly as there is areas in the frame that have no signs of undercoating. This is putting the driver of the vehicle at risk as well as the other drivers on the road. This is a huge recall that was issued for this model of year truck. Very common. The vehicle has not been inspected by the dealer as they refused to inspect it or even acknowledge the issue. There is no warning lamps on but it is visibly unsafe to drive.

The frame was not professionally undercoated and is actively falling apart. Super unsafe to drive.

There was a recall for the frame rusting out prematurely. Toyota had the recall until 2012. I did not own the truck then and it did not get fixed. Now I have a rusted out frame. Toyota is claiming they are not able to fix the frame due to it being 14 years later. They would however be able to keep the recall open if it is a safety recall. I don't know how a rusted out frame wouldn't be anything other than safety. The truck has less than 80,000 miles. What automobile should have a rusted out frame with less than 100,000 miles?!.

The frame is bad on driver and passenger side between the cab and bed. Auto body tech states there is no good metal to make the necessary repairs (welding new metal) to at this time. Inspection garage states it is a solid truck but will not pass inspection due to the frame’s condition. The vehicle has 106k miles on it with one surface area of rust. The vehicle has been well maintained and is mechanically in good condition. Toyota should have replaced the frames because they knew there was an issue. Can NHTSA help with a resolution?.

Frame rusted out causing gas tank to fall off truck while driving. Was sparking while trying to pull of to a safe spot on highway, tank was hanging on by the fuel line. Leaf spring also broke on truck do to rust. Cars were avoiding my truck on highway as sparks were coming from the gas tank shield scrapping the highway. Frame should have been replaced along with gas lines, and leaf springs during the recall in 2012 range. Toyota of york decided to just undercoat spray frame, prior to me purchasing truck from them. They never notified me (the consumer) of the recall that was current on truck.

The 2003 Toyota Tundra is known for severe frame rot due to improper rust protection, which led to a major safety recall. The excessive corrosion can cause rust holes to form in the frame, compromising the vehicle’s structural integrity. This can lead to frame cracking or even complete failure, making the truck extremely dangerous to drive. A weakened frame affects the vehicle’s ability to absorb impact in a crash, reduces stability, and can lead to suspension or steering failure. In extreme cases, parts like the fuel tank or spare tire can detach, increasing the risk of a serious accident.

In October 2024, my truck's frame exhibited significant rust, a defect that aligns precisely with a previous recall on this model. The rust has spread to critical parts, making the vehicle unsafe to drive. This directly threatens the safety of my son, who relies on this truck for transportation. The rust compromises the frame's integrity, risking structural failure and potential loss of vehicle control. This defect was not previously flagged by warning lamps or messages and was only recently discovered through visual inspection. This issue has been documented in the past and is consistent with a recall initiated a year ago. This recall specifically cited frame rust as a critical defect, and my vehicle is one of those affected models. Given the safety concerns, the severity of frame rust, and the recall history, the frame needs immediate replacement. This action is crucial to ensure my son's safety and prevent potentially life-threatening incidents on the road.

On 4/19/2024 I arrived for an appointment at corwin Toyota of bellvue, nebraska for inspection of my vehicles known recall of the frame due to excessive rust and potential failure due to a faulty manufacturing process. My vehicle is a 2003 Toyota Tundra sr5, access cab. Upon arrival, the service representative, and later corroborated by his manager, refused to inspect my vehicle stating "work had already been done on my frame". That is not true. I am the original owner of said vehicle and had it inspected in approximately 2010 after being informed of the recall, likely at a dealership in denver colorado where I was residing at the time. At that time was informed vehicle frame did not have excessive rust and no work was done. The vehicle was purchased in colorado springs from corwin Toyota (same dealership franchise company?), in 2003. Since then, the vehicle has lived in nebraska and iowa for most of its existence where salt is used on roads extensively in the winter. I was informed by the service representative at the dealership they will not look at it as they show it has already had repairs done to the frame as I stated. This is false. No work has been done on my vehicles frame at any point and is now experiencing significant frame rust. At some point, maybe at inspection in 2010, maybe later, that some work had been done making the frame ineligible for future inspection or repair or replacement. I am sure Toyota and its agents, Toyota dealerships, are highly motivated to exclude as many vehicles associated with this frame recall as possible. I am certain I am not the only one experiencing this fraud on the consumer. Please investigate whom allegedly did work on my frame, when, and what specifically. I expect the ability to have my frame legitimately inspected and actual repairs or replacement of effected part(s) as resolution. I will be contacting the manufacturer but expect the same run around without your direct involvement. Thank you in advance.

I just bought the Toyota I was told that he had brought this Toyota to a dealership and it was sent to har some sealant sprayed on frame to prevent anymore rust. The whole frame and the spare tire holder thing is total rusting out and the motor mounts are even rusting out is there a recall on his veichle if not there should be.

Frame is rusted and unsafe to be driven. I loved this truck but now what good is it?.

The frame on this truck is completely rusted. There are several holes and cracks in the frame. You can pull chunks of the rusted frame off with your fingers. It is unsafe to drive and is a hazard to other drivers there are many photos online of this model of truck that have broken in half when the frame has failed. There are stories of people who are driving this vehicle and it breaks in half while on the highway causing injury. I took it to our local mechanic in June who said this truck is unsafe. I contacted the iowa attorney general's office and made a complaint. They put me in contact with Toyota's corporate office who referred me to their brand experience center. They said it had to be evaluated by a Toyota dealer. I took it to the original dealer who sold this vehicle - wilson Toyota in ames iowa- on September 27, 2022. Their service center says the frame needs replaced. They said they would not pay for any repairs. They said this truck had two safety recalls to replace the frame but they said they expired in 2012. I spoke to Toyota's brand experience center again on the 27th and was told that my truck did not have any rust on it when it was taken in for the recall. Nothing was done to this vehicle when it was taken in for the recall repairs. There are many posts on Toyota forums that describe the same thing happening to other owners of this truck. - they are unaware of this condition of their truck frames until they bring it in to a reputable mechanic. The attached photos of this truck show the upper body is in good shape. But the frame is falling apart.

I have a 2003 Toyota tacoma 2 wheel drive the frame is rotted with only a 140000 miles on itand the manufacturer won't help me anymore so I don't know what to do with this vehicle now.

Frame is rotten. Recently purchased truck from a private party. Did not notice frame rust at time of purchase. It is bad. Can fit more than a marble through the hole in picture. Read up on it online. Common problem. Upon going underneath truck all frame is decaying. It appears it may have previously been sealed. Which may have cracked away and trapped moisture in just making problems worse. On top of that one thread I read stated guy took his truck to dealer and they told him by law they could not let him leave due to rust issue. Mine is an 2003 Toyota Tundra sr5 access cab 2wd terminator edition. Please help. I was also able to look up on Toyota website under owners and found a shop stated not safe to drive or even lift in November of 2020. And since then truck has only had about 700 miles put on. 120 miles was from guy driving it to me to sell to me. I’m now worried if I drive this in it’s current state that at any time it could break and cause an accident.

The contact owns a 2003 Toyota Tundra. The contact stated while having the vehicle repaired under an unknown recall, he was informed that the sub frame needed to be replaced. The manufacturer was informed of the failure but offered no assistance. The failure mileage was approximately 118,485.

Unsafe to drive so much corrosion on frame.

Recall id u7bs-ztw. Took in for airbag recall. Inspection of frame. Frame needs to be replaced and dealership would not let me have my truck back. They gave me a inferior loaner. . Took truck in first week of s January. As of 3-5-21 they have no repair schedule either!. Truck is at Toyota of muncie in. Alec baily is my service manager. Abaily@toyotaofmuncie. Work order number nc736011 and ncoo1101. I have been in contact with Toyota customer experience since February. Severe run around. Incident #s 210125000031, 210217000381,210304000232. National ref#s 210250103,2103042076. If it cannot be repaired I would like to know.

Crake in frame.

From 2001-2003 is a frame recall on these Tundra's due to massive rust issue. I went into my local Toyota dealership here in norfolk, va, and they gave me the run around saying I "missed the window" for this issue. Then I called corportate and they gave me a different reason, saying they "applied" anti-rust spray" in 2016. Which is not a thing. Clearly it did not work because there are massive holes in my frame. I would like them to own up and do my recall when so many other people I know have the exact same truck and got theirs done. I am active duty as well, and it frustrates me that they would treat a veteran like this. I brought up my spare tire latch being very rusted underneath, which there is also a re-call for. They said they could not do anything for me. 3 weeks later my spare tire flew off from my truck, thank goodness no one was injured.

Shock absorbers broken from frame. Part of frame broken.

My frame is rotten. It's totally unsafe.

Tl-the contact owns a 20013 Toyota Tundra. While having routine maintenance at an independent mechanic on the front wheel bearing the frame cracked into two places behind the cab without warning. The vehicle was undriveable. The contact called graham Toyota 1515 w 4th st, mansfield, OH 44906 (419) 529-1800 but was not diagnosed or repaired. The manufacturer was contacted who provided case 2001 021145 however, no further assistance was provided. The failure mileage was approximately 126,000. Ap.

In mid December, 2019, I was driving on the interstate and the spare tire dropped from under my 2003 Toyota Tundra. Fortunately, no vehicles were behind me at the time. I was so surprised to see that tire bouncing down the road behind me! that spare tire had never been taken from the carrier. I made an appointment with a Toyota dealer for inspection/recall in early February. They said the corrosion on the cross-member needed to be replaced but the spare tire carrier corrosion issue causing the tire to drop was only for recalls on the tacoma models, I was responsible for the issue. I feel this is a Toyota manufacturing safety issue that needs to be addressed. Do I have any recourse?.

Tl- the contact owns a 2003 Toyota Tundra. The contact stated that his vehicle was leaking differential fluid from the housing wall of the rear end of the vehicle. The contact took the vehicle to a mechanic where he was informed that rear end housing needed to be replaced. The contact took the vehicle to continental Toyota 6701 south la grange road, hodgkins, IL 60525 (708) 716-4497 where he had had his vehicle serviced prior for a recall(09v444000-structure) for rust. The contact was informed that due to the age of the vehicle, they will not offer assistance for the repair of the vehicle. The manufacturer had been notified of his failure and also informed him that they could not offer assistance. The vehicle had not been repaired. The failure mileage was 250,000. Jo.

The contact owns a 2003 Toyota Tundra. While driving, the trailer hitch became detached. The contact coasted the vehicle to the side of the road and noticed that the hitch dropped low to the ground and was bent. The contact used the trailer jack to lift up the trailer and straighten the hitch to the receiver in order to drive home. The contact stated that the trailer hitch was bolted to the reinforcement bumper, which was corroded. The contact was concerned the passengers in the vehicle would not be protected in the event of a crash. The contact removed the trailer from his vehicle and placed it in the back of the vehicle. The vehicle was taken to new country Toyota of saratoga springs (located at 3002 NY-50 building # 1, saratoga springs, NY 12866, (518) 584-7272) where it was determined that the reinforcement bumper was not included in NHTSA campaign number: 09v444000 (structure). The recall only included the frame and all the crossmembers; therefore, the dealer could not assist. The vehicle was not diagnosed or repaired. The manufacturer was notified of the failure and provided case number: 1906120378. The approximate failure mileage was 114,000.

A few years ago I bought a used Toyota Tundra with 70k miles on it thinking I was getting a reliable vehicle with lots of life left on it. What I got was the most unreliable expensive piece of crap I have ever owned. It even nearly ruined our honeymoon. We took the truck on a road trip to see the southwest and kick off our marriage. It was very exciting thanks to Toyota. At the grand canyon we had the pleasure of hunting down the last overpriced bottle of power steering fluid. Rather than relaxing at the south rim I had to figure out how to limp the truck to the nearest shop. That was over $1200 out of our budget. The next obstacle was even more exciting. We discovered the back tires where ready to fall off and the front wheels had developed some issue also. So we limped the truck to elk city oklahoma in the midst of tornado warnings. We even got to spend the night in a run down motel 6. I think they rented rooms by the hour. That was another $1400 over our budget for a two day stay in scenic elk city. At least we got a free loaner from the folks at smith family Nissan. It's more than Toyota has done for us. I had to drive up to keene to just get pushed right out the door politely. They could have at least saved me the trip by simply returning my email. We got the same treatment from Toyota corp. And for a souvenir we are left with a very expensive piece of scrap metal in the driveway. It appears as though Toyota cheeped out on the steel for the frame. Cheap chinese steel. The solution was to spray some cheap crap on the frame and cover up the problem. It won't be long before it breaks in half just sitting in the driveway. Thanks Toyota for all the help and the great customer service. You sure know how to take care of customers. Thanks to Toyota's patch job the frame issues did not appear in a car fax report.

Frame recall inferior steel used on the frame has led to premature failure and rot. Toyota applied a sealant to the frame to address the rust issue. The sealant was also an inferior product and did not adhere to the frame. Because Toyota considered the recall closed there was no warning to indicate a hazard could exist. A recall will not show up on car fax if the manufacturer deems the recall is complete. Toyota's position that road salt is the cause of the premature frame rot ignores these facts.

Takata recall, I was involved in a collision with my Toyota Tundra when a Nissan altima failed to stop for a stop sign. At witch point my air bags did not go off. The truck is totaled and so was the Nissan! I was driving east on quincy Ave. And the Nissan was driving south on b st. When she failed to stop at the stop sign.

Tl-the contact owns a 2003 Toyota Tundra. The contact stated that while driving at 65 mph there was an abnormal dragging noise emerging from the vehicle. Upon exiting the vehicle he noticed that the fuel tank was rusted and detached. The check engine indicator light was illuminated. The contact called the local dealer don moore Toyota 4216 frederica st, owensboro, ky 42301 (270) 926-2500 who informed the contact to tow the vehicle . The vehicle was not diagnosed or repaired. The manufacturer was contacted however no further assistance was provided. The failure mileage 129,000. Ap.

Rear cross member that holds on spare tire is completely rusted. Toyota refuses to replace because the recall has expired.

Tl the contact owns a 2003 Toyota Tundra. While the contact was servicing his vehicle, he looked underneath and noticed that the sway bar was rusted along with the entire frame. The contact stated that the vehicle exhibited the same symptoms as listed in NHTSA campaign number: 09v444000 (structure). The vehicle was not taken to a dealer to be diagnosed or repaired. The manufacturer was not notified of the failure. The failure mileage was approximately 100,000.

Frame corrosion was not properly addressed during 2012 recall. As a result the frame has corroded in multiple areas and the brakes just failed due to brake line corrosion. Toyota is refusing any additional claims for damages. However they should have done more to address the frame corrosion during the 2012 recall.

After mechanic recently inspected under side, it was found that the frame had significant rust and rot. Frame is not expect to maintain structure for very long.

Tl- the contact owns a 2003 Toyota Tundra. The contact stated upon inspection of the vehicle at an independent mechanic they were made aware of severe corrosion on the frame. Cobb county Toyota located 2111 barrett lakes blvd, kennesaw, GA was contacted and confirmed the corrosion however they refused to perform the remedy under NHTSA campaign number 09v444000(structure) due to the vehicle being previously inspected under the campaign. The manufacturer was notified of the failure where they confirmed the NHTSA campaign was performed. The failure mileage was 78000. The VIN was not provided. Kh.

~tl the contact owns a 2003 Toyota Tundra. While the vehicle was undergoing recall repairs at galaxy Toyota (750 NJ 30, eatontown, NJ 07724), the technician diagnosed that the front of the frame was completely rusted. The technician stated that the failure was not included in a recall. The manufacturer was made aware of the failure and stated that there was no recall. The contact was instructed to sign a waver, noting that the vehicle was unsafe to drive. The vehicle was not repaired. The failure mileage was approximately 295,000.