Frame Rust problems of the 2003 Toyota Tundra - part 1

The cross member on my 2003 Toyota Tundra (part no. 51206) is exhibiting extensive and premature rust and corrosion at both connection points with the main frame rails such that the main frame rails have rusted through, leaving multiple holes approximately the size of a quarter. The cross member supports the fuel tank, among other components, and thus the corrosion poses a significant safety hazard. As a result, the vehicle, which is otherwise in satisfactory and operational condition, failed its annual state inspection. Toyota previously applied a rust inhibitor to the frame under its limited service campaign which was intended to remedy the defect, but such application failed to prevent the premature corrosion and Toyota has since refused to remedy the defect.

My 2003 Tundra frame is rusted and cracking. I believe this should be covered by the limited service campaign (lsc) a0f.

I recently had an exhaust leak on my truck and would occasionally hear some clunking noises under the vehicle. I went under the truck to investigate the extent of the exhaust leak and noticed that one of the sway bar links was no longer connected and that one end was rusted off. I ordered replacement parts and tried to jack the vehicle up under the frame and I heard crunching and saw the jack pressing into the frame from the bottom and crumbles of rust came showering down. I relocated the jack to a different portion of the frame and continued to jack it up and more creaking of the frame and rusty parts broke free and fell to my driveway. The frame behind the driver's side front wheel is badly rusted and has lost its structural integrity. There are several 5"+ horizontal and vertical "cuts" into the frame both on the side and bottom surrounding the nearby front cross-member. This excessive rust corrosion compromises the vehicle's safety, stability, and crash-worthiness. We can no longer use this truck for its intended purpose of hauling a heavy payload or towing a trailer which were engineered by Toyota. This has also greatly affected the value of the vehicle. We took the vehicle to the Toyota dealer in westminster, MD and they performed the anti-rust spray treatment to the frame in 2010 under the limited service campaign which obviously didn't work. The exterior painted surfaces of the body are all in excellent condition as I applied a coating of wax at least annually. The truck has just now reached 90,000 miles and I don't feel that I got the value out of the truck for what I paid brand new for it back in 2003 when I trusted the Toyota name. I recently contacted the Toyota dealer in westminster, MD again and I was told that the recall for the frame expired in 2012 and that there was nothing else they could do.

2003 Toyota Tundra showing severe signs of frame rust and corrosion damage rendering vehicle unsafe to operate on a public roadway. This vehicle in every other way gas been manufactured to perform for many more years excepting the foundation of the vehicle, the framework. Many, many of these vehicles are in use on american streets by individuals and families who are in dire risk and posing a life threatening risk to all other drivers on the road.

On 12/05/11 newark Toyota completed recall ssc90m phase 2-crc application to my rusted frame. Almost immediately I notice a bonding failure and delamination of the crc application. By November of 2013 I asked the same service lane manager, bill c. And the technician that performed the work to inspect the failed application. I asked the technician why it failed and he stated "I did not prepare the surface correctly before I placed the application". I appreciated his honesty but was told then that there was nothing else they could do about it. My frame is now very rusted so I asked bill c. To reinspect my frame on 12/5/19 while my Tundra was in for a takata airbag recall. William told me that he had a manager inspect my frame and that no perforations were found (please see all attached photos). They did not mention the catastrophic failure of the frame c channel lower flanges. This exponentially expansive corrosion has reached the leaf spring bracket flange rivets (see photo 8810); catastrophic failure of the rear axle assembly will result. I am a mechanical engineer with extensive training and experience in corrosion related failure. This frame and vehicle are unsafe! on 12/21/19 I emailed this information, including the photographs and copies of all service records, to the Toyota customer care center. They emailed me back on 12/28/19 and asked me to call them. The Toyota representative, jeffery m. , called my dealership and told me that the frame was not perforated so I am not eligible for the frame replacement recall. I asked jeffery multiple times if the dealer said the frame is safe or not. He refused to answer that question and would only state that my frame is not perforated. The NHTSA/Toyota 10mm perforation criteria is inadequate and the phase 2 application bonding failure exacerbated moisture and road salt retention.

2003 Tundra subject to frame rust deterioration recall which ended this year 2019. This vehicle underwent this recall inspection at Toyota dealership. I was told "paint with rust inhibitor will solve problem". Recent inspections x2 by frame mechanics (now a few years later) resulted in immediate recommendation to not drive due to danger of imminent frame collapse. This vehicle has only 118,000 miles and is otherwise in very good condition. I am sure many others are in same condition - not having frame replaced by manufacturer, or misled by manufacturer's service center. Many accidents likely will occur in future. Owners of these vehicles need to be warned of this danger.

The entire frame is rusted - to my shock and I just failed inspection but the truck is gorgeous and runs great with all new tires. I'm currently low income and wonder how the frame recall was missed but the airbag was replaced. Please advise and thank you.

Frame is completely rusted through. Car has only 130k miles. Toyota denies culpability, frame is made of inferior material not able to withstand use.

A recall letter was sent for 2003 Tundra for undercoating. Vehicle was taken to dealership and was there for three days. I was told nothing else was needed. I brought attention to dealership about frame recall. I was told my vehicle was not under that recall although the year and model was on the site. Second issue of concern, entire steering line replaced. There was a lack of power steering. Vehicle housed for three days at dealership. Fast forward today, 25 September was brought to my attention by service manager of large amount of frame rust and vehicle was not road worthy. Layers of rusted metal crumbled in manager's hand. As a consumer preventive maintenance repairs have been made. I have asked the dealership for help to resolve ongoing concerns. I am a female retired veteran pleading for help. I love my vehicle performance is the reason the mileage is 260,000 (+). Your attention to this concern would greatly be appreciated.

I had a safety recall for corrosion and had it repaired at the dealership in July, 2015. Recently I returned to the dealership for an exhaust leak. When they put it on the rack they noted several areas on the frame which had rusted all the way through. The mechanic informed me the truck was unsafe to drive and the frame needed to be replaced. I contacted Toyota and was told my VIN was not part of any recall and therefor Toyota would not replace the frame. I believe the same inferior steel was used on my frame as was on the recalled Toyotas. I live in virginia which while we don't experience the large amounts of snow here, we are still considered a northern state per Toyota. The truck has never been in an accident and was used as a daily driver and now will be a total loss.

My complaint is with Toyota motor company and their admission but yet no resolution to a known problem. My story of this Toyota truck begins with my son owning this Tundra for about 5-7 years then selling me, his father the same Tundra. Before buying said truck I was assured it was of god structural integrity, due to an inspection at a Toyota dealership. Upon inspection they did find that the frame had visible rust and proceeded to treat it with anti-corrosion. Forward to three weeks ago a local inspection was to be done in which I was told that it would not pass due to frame problems as it was not safe to drive. Toyota engineers know that the frames are going to rust because no exterior application of any anti-corrosion is going to prevent any corrosion within a tubular boxed frame. I was refused any solution from Toyota, who have previously admitted that these particular trucks all have the same issue. How can you help with getting Toyota to resolve this completely instead of passing the little guy aside?.

The frame is rusted through to the point the truck cannot even be jacked up. It has been maintained and garage kept,it is not due to a lack of care for the vehicle.

Frame rusted to the point of being non-repairable and unsafe to drive.

A few years ago my truck was recalled for rust of the frame. I took it to the dealer and they decided it was fine and spray coated the bottom of the truck as a remedy for the recall work, where other trucks were given new frames. In my state inspection this month I was advised that there was substantial rust problems (holes) on the frame in the front upper part of the frame, just 10,000 miles since the recall remedy was done. The dealer tells me they can do nothing, it is a Toyota problem, Toyota tells me it is a dealer issue since they already "repaired" the vehicle under the recall. The work they performed under the recall was not sufficient to make their trucks safe, and I believe another recall must be done and the frames need to be replaced as this is an unsafe situation both to myself and others on the road.

Entire frame has severe rust despite anti-rust/corrosion inhibitor applied in 2010-2012. Small holes are now present in frame and the vehicle only has 108k miles. Recently, the power steering rack and pinion had to be replaced, as it rusted out. The technician noticed rust on other suspension components, indicating that rust had made the system weak and brittle. Copious amounts of corrosion inhibitor has now made it almost impossible to obtain a correct alignment. The rusted frame will soon, if not already, diminish the vehicle's safety. Toyota instituted a frame recall circa 2010 for just this issue. Somehow this VIN was omitted. The corrosion inhibitor has proved ineffective. I am requesting that NHTSA demand Toyota institute another recall for the excluded vins. These omitted Tundras, in their current poor frame condition, present a hazard to drivers and other motorists and must be repaired.

The contact owns a 2003 Toyota Tundra. While undergoing routine maintenance, the technician stated that the frame was severely rusted and the vehicle was unsafe to drive. The vehicle was taken to pearson Toyota (12978 jefferson Ave, newport news, va 23608, (757) 874-6000) where it was diagnosed that the frame was in poor condition and the vehicle was unsafe to drive. The frame needed to be replaced. The vehicle was not repaired. The contact mentioned that the vehicle was repaired in 2012 per a manufacturer recall for frame rust in which an anti-corrosive agent was sprayed onto the frame. The manufacturer was notified and did not assist. The failure mileage was 137,430.

The frame is rusting apart will not pass state inspection.

Tl-the contact owns a 2003 Toyota Tundra. The contact stated that while stationary, the contact's dealer noticed the frame was rusted from the inside out with holes in it. The contact stated that the frame was undercoated for rust and corrosion on July 12, 2012. Heritage Toyota of burlington, vermont discovered the severe frame rust and stated that the contact would have to pay for a new frame. The manufacturer was made aware of the issue and stated the frame was undercoated and that they had done what was required in relation to the vehicle. In addition, the manufacturer stated that the vehicle was out of mileage warranty coverage. The failure mileage was approximately 150,000. Ad.

The contact owns a 2003 Toyota Tundra. While driving unknown speeds. The vehicle began to sway. Additionally, the frame was rusted and chunks of the frame was detached. The vehicle was taken to an independent mechanic. The local dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was notified and opened case number: 1710030430. No further assistance was offered. The VIN was unknown. The failure mileage was 135,000.

Excessive rusting of frame on 2003 Tundra, car was taken multiple times to dealership, issue was not fixed at all. . . . I have contacted Toyota but have gotten the run around. Please advise.

My vehicle has sustantial frame rust which affects the safe operation and the resale/trade-in value. Toyota refuses to offer any remedy because the frame replacement program ended in 2012. My vehicles frame passed a frame inspection in 2011 by a local dealer. I took them at their word. I dont feel that the frame on a 12 year old vehicle should havae such a short service life. This is a hardship for hundereds of Tundra owners who have otherwise good vehicles that are now potentially un-safe and utterly worthless. The dealer did offer to patch the frame in one area but it is corroded in several areas. Any assistance would be greatly appreciated as Toyotas actions did not go far enough.

Bad frame rust bad suspension rust bad differential rust bad spare tire rust. If rust condition gets worse the possibility of suspension failure is very real. Some of these models need to be recalled or bought back before there is injury or death.

The contact owns a 2003 Toyota Tundra. After inspecting the vehicle, the contact discovered that the frame was rusted. The contact mentioned that the failure occurred after the vehicle was serviced under NHTSA campaign number: 09v444000 (structure). The vehicle was taken to the dealer where it was diagnosed that the frame needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was 149,000.

The contact owns a 2003 Toyota Tundra. The contact stated that the vehicle was taken to an independent mechanic and a dealer where the vehicle was deemed unsafe to drive. The technician stated that the frame was rusted and needed to be replaced. The vehicle was not repaired under NHTSA campaign number: 09v444000 (structure). The manufacturer was made aware of the failure. The failure mileage was approximately 170,000.

Tl-the contact owns a 2003 Toyota Tundra. The contact stated that the rear of the frame was rusted and corroded. The vehicle was taken to an independent mechanic. The technician stated that the entire frame needed to be replaced. The vehicle was not replaced. The manufacturer was notified of the failure. The approximate failure mileage was 92,000. Pam.

Upon inspection there is total rust of the frame and bolts on the suspension. Unusual tire wear. I have read about some recalls but this is an exceptional low miles vehicle (less then 50,000) and it is found to be in unsound condition and current value should be at least $18,000.

Frame has several rust perforation holes. Toyota refuses to repair. Vehicle bought used in March of 2013.

The contact owns a 2003 Toyota Tundra. The contact stated that the vehicle was taken for state inspection and the contact was told there was severe rust on the frame. The contact referenced NHTSA campaign id number:09v444000(structure: frame and members: underbody shields) and spoke with the manufacturer but was told that the recall was closed. The failure and the current mileages were 47,000. Updated 08/28/lj.

The contact owns a 2003 Toyota Tundra. The contact stated that the entire frame exhibited rust and corrosion, which caused extensive damage to the rear differential casing. The vehicle was taken to an authorized dealer for diagnosis. There was a recall associated with NHTSA campaign id number 09v444000 (structure: frame and members: underbody shields). The part was ordered and the contact was advised that it would be available within six to eight weeks. The contact expressed that the recall remedy should include the replacement of the rear differential casing. The manufacturer was not notified of the problem. The approximate failure mileage was 46,000.

2003 Toyota Tundra with low mileage and well-maintained but excessive frame rust that will eventually become unstable.

2003 Toyota Tundra with excessive frame rust including all rustable components with any connection to the frame. 2011 maine state inspection failed due to rusted emergency brake. The emergency brake had been repaired two years prior for same reason (June 2009).

2003 Tundra has excessive rust on frame. Deal offers no remedy.

My fathers 2003 Toyota Tundra getting checked out recently by a local mechanic when he was made aware that the frame is excessively rusty. With this information the truck was brought to a Toyota dealer for inspection. The dealer stated there is so much rust the vehicle the vehicle is unsafe to drive. Dealer also stated there is nothing Toyota will do about it until the rust actually creates a hole in the frame. My parents are in there seventies on fixed incomes, they don't have a choice but to operate this unsafe vehicle. If a dealer is able to state a vehicle is unsafe to drive Toyota should back the determination of the dealer and do everything possible to remedy the problem. My parents were told to bring the vehicle back after a hole rust through the frame and then Toyota will do something about it. A 2003 truck should not have rusted to the point of being unsafe in a 7 year period. Please help my parents.

I own a 2003 Toyota Tundra that has severe frame rust. Big pieces of metal are flaking off, sooner or later some component attachment point will fail. The rest of the underneath, and truck as a whole, is rust free. I religiously wash the underside of the truck. There is a defect with these frames.

Rusting frame and spare tire falling off.