Frame Rust problems of the 2004 Toyota Tundra - part 1

The frame is rusted to the extreme that previous owners have already had it repaired on the drivers side just behind the front axle for the sway bar to mount. I have found the same issue of rust through the frame is now on the passenger side and bout to do the same thing. I also find extreme rust just in front of the rear axle. Extreme rust holding the transfer case in the vehicle is very thin also.

Vehicle failed its yearly state inspection due to severe rust making the frame structurally compromised. The vehicle was inspected by Toyota in 2014 and treated with a corrosion resistant compound under a limited service campaign. Six years after the application Toyota now advises the frame is structurally compromised due to severe rust.

Yes I have a 2004 Toyota Tundra crew cab truck is in good shape but recently found my frame is rusting away I've contacted Toyota because they had a recall before but they will not do anything about it I've read some Toyota forms and apparently this is not a rare case this is unbelievable this is the reason people are killed going to work frame just brakes I want something done before that someone killed is me.

Truck was purchased brand new. It was brought to dealer for recall and they did not resolve the issue. Now recall is expired and vehicle is dangerous to drive and frame is rusted and there are holes. Almost had an accident when I turned and went down a hill and the brakes did not hold. Other incidents have occurred over the years.

Frame is so rusted out that the front suspension has nothing to support it. The truck can no longer be safely driven. Toyota had me take the truck in and have the frame checked for rust in 2015. At that time they told the frame was good. I contacted the local dealer on 2/17 this year and they could not help me and that I would have to contact corporate. I contacted them same day and was told since they checked it once there was nothing else they could do for me. Hard to believe the frame could so completely deteriorate in that five year period. I know I'm not the only one having this problem. I hope something can be done to help all these people out.

All my front suspension components failed. I noticed that the frame had rusted through near the front wheel passenger side and has buckled and shifted as a result. My upper and lower ball joints and cv axle were damaged while my truck was in motion turning into the safeway gas station chester MD. February 9 of this year when the suspension failed to support the truck. The passenger side ball joint and cv axle were damaged. Tie rods and sway bar stabilizers were all worn and broken as well.

I had recently purchased a 2004 Tundra with knowing about the recall for frame rust. I believed Toyota had completed the recall and fixed the problem. Not long after owning the vehicle, I noticed a spot of rust bubbling through the anti corrosion coating. After further inspection, the frame is completely corroded through and cracked. This vehicle was meant to use for travel with my family in it and now it's not safe to drive at all.

Tl-the contact owns a 2004 Toyota Tundra. The contact stated that while performing an inspection of the rear suspension of the vehicle, the contact became aware that the sub frame, the suspension support, and the spare tire enclosure was extremely corroded. The contact also stated that the spare tire had separated from the vehicle. The contact was unaware as to when the spare tire was lost. The contact stated that the vehicle was inspected in 2015 at mccarthy Toyota of sedalia, 3110 w broadway blvd, sedalia, mo 65301, (660) 826-5400, under a manufacturer communications for frame rust. The contact was informed at that time that the vehicle showed no excess in corrosion. The vehicle was not repaired. The manufacturer was contacted and informed of the failure. The approximate failure mileage was 150,000. Ah.

My 2004 Toyota Tundra sr5 4wd crewcab is showing significant sign of frame rust that's compromising the structural integrity of the frame and thus operational safety of the vehicle. Despite being barely used over the years and at just 144k miles, in certain sections of the frame there are holes where the frame has rusted through. The ride quality feels a bit wobbly, even after examination and rectification of other mechanical issues (suspension, joints, etc. ) upon further research, this issue seems to be pervasive issue among first generation Toyota Tundras made in the us of this period. The result is very premature rust and complete disintegration of the truck frame. The primary cause was poorly made truck frames from a Toyota vendor that ended in a class-action lawsuit. Toyota has offered extended recall to inspect and replace all affected truck frames as appropriate. I seek to be included in this program and proper assessment by an authorized Toyota dealer. As this issue affects both the resale value of my vehicle and more importantly the operational safety of this vehicle, I request that the issue be expedited by the right authorities. Thank you!.

Purchased vehicle from private party. Previous owner informed us of frame recall preformed on vehicle 3/2014 stating Toyota sprayed frame with rust inhibitor, he complained that he wasn't satisfied with the results. Frame is now unsafe. Reinspected by Toyota 8/2019, frame is unsafe but the recall has ended. Vehicle has 133,000 miles and is useless. Toyota put a bandaid on the issue and called it fixed.

Tundra frame rot and rust. In 2014, we purchased a 2004 Toyota Tundra with 90k miles on it for our 16 year old son to drive. Near the time of purchase in 2014, the truck frame was sprayed by Toyota under their limited service campaign by the person selling us the vehicle. To our surprise,the truck recently failed inspection for a rusted/rotted frame. The current mileage is 122,892. I contacted Toyota and they claim that they addressed the issue with the spraying back in 2014 and are not able to assist further. Nhtsa, please help us. Toyota will not stand behind the defective frames. Please step up and address this issue with Toyota.

Frame has rust holes, per Toyota mechanics, my frame continue to rust out cannot pull a trailer with bad frame. Toyota will not honor their work. I am a loyal Toyota customer and has a lot of work done by Toyota dealer. I need my frame repaired to continue using my truck.

Still having major rust issues on frame following 2015 Toyota recall to coat the frame. This is a major safety issue and I don't know why Toyota stopped at the year 2003 on frame replacements when obviously 2004 year just as bad. Everytime I back out of my garage I see rust debris. Come on NHTSA do your job and recall these safety concerns !!!.

Our 2004 Tundra with 65,000 miles was recently identified to have a rusty frame. We put it into the dealership to see what could be done. The dealership deemed it rusty to the point that it could not be coated and was a loss. We contacted Toyota and they said the frame programe was for 2000-03 and is now expired and our 2004 wasn't covered. This is a major safety issue. There are hundreds of thousands of trucks on the road that are still affected by the faulty frames and Toyota is not doing anything. This leaves consumers with a vehicle that is worthless and dangerous. A recall is needed to protect our families and the roads we travel on. We are going to start seeing vehicles come apart on the roads and killing people.

2004 Tundra frame rusted and will not pass inspection. Inspector noted rust holes larger than a quarter.

Excessive rust on sub-frame of vehicle; frontal sub-frame completely rusted out on vehicle with no apparent body rust; garaged throughout its history; and with less than 100k miles; rear frame rusted.

I have a 2004 Toyota trundra with only 93,000 miles on it , that has never hardly ever set outside, with frame rust behind front wheels that I can stick my finger though it. . . . It is unsafe to drive on the highway,, and I have not had a recall on frame rust repair. . But have had a air bag and over spare tire support recall . . I only notice this when getting a tire repaired,in April of 2019, it was pointed out to me by repairman, , don't know how long it's been this way.

Tl the contact owns a 2004 Toyota Tundra. While the vehicle was undergoing routine maintenance, the contact was able to see that the frame was rusted. There were no warning indicators illuminated. The dealer and manufacturer were made aware of the failure. The vehicle was not diagnosed or repaired. The failure mileage was 224,300.

My frame is rusting almost into, I don't think it was inspected well, and now the rear axle housing is rusted so bad it's leaking fluid.

Tl-the contact owns a 2004 Toyota Tundra. The contact had rust on their frame. The bottom frame had developed bubbles and and is rotting. The vehicle was taken to lakewood Toyota 1118 ocean avenue rt88 lakewood, NJ 08710 732-364-9000 where no assistance was provided. The vehicle was not diagnosed or repaired. The manufacturer was made aware of the issue and no assistance was provided. The failure mileage was 190,000. Jw.

I recently took my truck into tarbox Toyota in rhode island for a state required inspection. I purchased my Tundra from this dealership in 2004. The truck failed the inspection. A major defect was rust related holes in the frame. When the tarbox dealership installed a rust preventing undercoating 2-1/2 years ago, I asked and was informed that there were no holes in the frame. As you can tell by the attached pictures, the frame has substantial rust and a hole in the same areas experienced by other 2004 Tundra owners. It is also obvious by the pictures that the undercoating installed to prevent rust failed and peeled off--and in fact covered up existing rust areas--rather than provide protection against future rust damage. I was informed by the dealership that Toyota would not do anything to address the rust damage on my truck--or take responsibility for enhancing the rust damage caused by improperly coating the frame over existing rust. In fact, the advice offered was to just "lease a new vehicle. " my safety concern is that in addition to myself, third party owners may not be aware that Toyota covered up rusted frame damage with the undercoating installed over rust--and I do not know if there are additional holes in the frame that are not visible.

Tl-the contact owns a 2004 Toyota Tundra. The contact stated that the vehicle was taken for a state inspection. The contact was informed that the entire subframe was rusted through. The contact was informed that the vehicle was unsafe to operate. Hoselton Toyota located at 50 marsh rd, east rochester, NY 14445, (585) 381-8530, was contacted and informed of the failure. The contact was informed that there was an extended warranty for a anti-corrosion spray of the subframe that expired in 2015. The manufacturer was contacted and was informed that since the warranty period was exceeded, there would be no further assistance. The approximate failure mileage was 79,000. Ah.

Frame is rusted in my 2004 Tundra and Toyota won't remedy the the problem . The frame is the same as the 01-03 but the recall only applies to those years which is ludicrous. I have heard of Toyota replacing some frames for 04-06 but they won't even look at mine.

Rusted holes in frame.

My frame has rusted to the point it broke,I believe it falls under the 1st generation frame as the 2003 models. I went for an inspection and it failed due to frame.

I purchased my 2004 Tundra from a Subaru dealer last summer and did not realize it was included in the many trucks which had premature frame rust. Toyota admitted it was an issue and stated that the previous owner had undercoating put on the truck paid for by Toyota, however, clearly this was ineffective and a temporary band-aid for inferior metal. Toyota stated that they would not do anything to correct this problem, and as a college student, I need access to a safe vehicle. I am afraid to drive this truck as if it is struck by another vehicle, I do not believe it would withstand the impact due to severe frame deterioration. I understand the truck is from 2004, however, the rust on this frame is beyond a normal rate. Meanwhile, I am out $16,000 and the rust has overtaken the truck greatly within the past year. Toyota still refuses to help despite my gas tank needing to be replaced and my pictures of all of the deterioration. Despite doing my research and seeing how well-maintained this truck was, the frame itself has rusted beyond recognition and yet, the other parts remain relatively intact. This vehicle is otherwise in extraordinarily good shape and is and was well-maintained. It only had 58,000 miles on it when purchased and still has less than 80,000 miles.

I have excessive rust on my frame. I has holes in frame and almost rusted in two. Toyota will not do anything about issue. Not sure what to do about it. The truck runs great and the body is in great shape. Frame is in bad condition.

My Tundra was under the frame rust recall in 2014. Toyota's claim was that the salt from the roads caused the severe corrosion. As we all know this was actually from the use of sub standard steel in the manufacturing process. My frame was actually DE laminating, not just simple surface rust. When I had taken it in for inspection all that was done was wire brush the frame and spray with an undercoating. Now just a little under three years later the coating is peeling of along with more layers of metal. Most of the people I know with tacomas and Tundras had their frames replaced when theirs were taken in. So now I have a truck that is no better than it was before. Also most of the chassis components are rusting out prematurely as well. My spare tire winch mechanism (carrier) bracket was about to rust through, luckily I caught this before I possibly could have dropped my spare when traveling on the interstate. I would appreciate someone from nhtsb taking a look at my vehicle to see the extent of what I am talking about. My vehicle only has 67,000 miles on it. I did contact Toyota service about this, but their answer was you have what you have and they will not do anything further. I'm sure I'm not the only one in this situation. My frame should have been replaced. Thanks.

I just got off the phone with a case manager name marquita from Toyota. I had called three days earlier and was told a case manager would call. I received no phone call, and had to call them myself. My Tundra is one of the vehicles affected by the lack frame protection resulting in a severely rusty frame. I had the frame inspected by a local Toyota dealer and was told that the undercoating that was meant to solve the problem was poorly applied. Huge chunks are my frame are falling off and the frame is exposed causing it to continue to rust. The master technician brought me back to show how the frame was not originally prepped and the undercoating was thinly applied. So back to the conversation with the case manager. Marquita proceeded to tell me the undercoating was a one time remedy to the frame rust problem. Whether or not the undercoating was done well or not, Toyota is not willing to rectify a poorly done "solution". The same rusty frame is under all the slime they applied and now it is going to continue to get worse. This is a known issue, and I believe Toyota sued the manufacturer of the frames. And me and the other owners are left to rust.

In febraury 2014 I received a recall for the frame rusting on my truck, I brought the truck to Toyota of keene for inspection and they undercoated the frame. They did a lousy job of undercoating and I complained to Toyota, because they did what they were instructed to do they would not review or reinspect the vehicle. My Tundra had 58,970 miles on it when it was undercoated for the rust issue, it now has 66,406 miles on it. The whole frame is rusted, so bad when I drove down my driveway big patches of rust fell off of it. Open the hood and you see nothing but rust. I do not feel like this vehicle is safe for the road but because of my health situation I cannot afford to get a new vehicle. All I want is the vehicle to be repaired the way it should have been in the beginning. The spare tire holder has rusted to the point of loss of the use, carrying the spare tire in the bed on the back of the truck, the gas tank door rusted right off so I had to get a new door, I just need someone to help resolve this unfortunate rust bucket of a situation.

Tl-the contact owns a 2004 Toyota Tundra. The contact stated that the vehicle was taken to an independent mechanic for schedule maintenance and was advised that the repairs can not be performed because the frame was severely rusted. The contact also stated that the vehicle was evaluated by the dealer two and half years ago and the diagnosis was that the frame was alright. The vehicle was diagnosed a second time and the diagnosis rendered by the dealer was that it was not severe enough for the frame to be replaced. The manufacturer was notified of the failure. The contact was advised by the manufacturer that the recall had ended. The vehicle was not repaired. The approximate failure mileage was 135,000. Bp.

Front suspension stabilizer bar rusted off of frame, resulting in large, structurally compromising hole in the welding location on the frame. When turning into my driveway I heard the stabilizer bar detach from the frame. The driveway is modestly sloped which caused my left wheel suspension to flex as it would in any ordinary driving conditions. Upon inspection of the frame, I noticed that the detachment resulted in a small hole. Upon cleaning up the effected area, however, I noticed a massive hole in the frame. Little did I realize that I had been driving on a completely unsafe vehicle this whole time. Toyota has a recall in place for these exact same components for 2000 -2003 Toyota Tundras. Why isn't there a recall in place for these? they are the same parts. The first two photos are before wire brushing the area. The last two are from after brushing them.

Observing excessive frame rust and frame decay. Concerned about structural safety based on the significant frame degredation.

Frame rust, the entire frame is rusted and the spray of the under carriage is falling off and now rusting even more.

Found 4 inch rust hole through frame on 2004 Tundra with 80,000 miles that was treated with the coating in 2014. Toyota corporate said there is nothing they will do to fix it as the recall or whatever expired in 2015. How convenient. Frame rot is a safety issue! this is a family vehicle! if not repaired, the frame will fail.