general problems of the 2005 Toyota Tundra - part 1

This report addresses the critical structural integrity concerns related to excessive corrosion, and frame material loss affecting the main ladder frame chassis. The degradation of the frame members poses a significant and immediate safety risk, including potential catastrophic structural failure, detachment of critical components, and failure of safety systems (e. G. , braking and fuel lines) mounted to the frame. Location: mid-frame section (beneath the cab) and rear sections (near the leaf spring mounts and rear axle).

Frame is rusted beyond repair both in the front and rear of the truck. Fuel tank strap is rusted threw and fuel tank is hanging by one strap and not far from the ground.

This vehicle was recalled for frame rust issues. The dealer under coated the frame in-lieu of replacing it, as they have done with so many others. Now I'm facing a safety issue, as the frame has rusted through in critical areas. The major concern is if the frame snaps in half while under high speeds causing an accident and potentially injuring other and or myself. I have contacted the manufacturer and they provided a case number (240530000550). The dealer is aware of this issue and they were the ones that recommended contacting this organization as well as the manufacturer.

The contact owns a 2005 Toyota Tundra. The contact stated that while driving at 35 mph, the driver’s side front ball joint detached causing the front driver’s side wheel to bend inward. No warning lights were illuminated. The vehicle was towed back to the residence which caused damage to the fender. The dealer was made aware of the failure and informed the contact that the vehicle was previously repaired under NHTSA campaign number: 07v013000 (suspension) however, the failure occurred. The vehicle was not diagnosed or repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 290,000.

Frame corrosion through out the entire frame. Recently the steering rack broke away from the frame cross member. Now every time I turn the wheel there is a popping sounds and the steering feels loose compared to what it did before the sound accord. There is also a hole in the back of the frame behind the back tire. My attached tow package ripped sections of the frame and caused crack to extend towards the front of the frame. The fuel tank straps are also severely corroded.

Frame rusted thru to point it is unsafe to drive.

Frame and suspension is rotted away badly was recall on frame in 2005.

Toyota did an inspection for frame rust years ago, but mine is now rusting out I believe it should have been swapped at the time of the recall.

The frame is rotted thru in multiple spots. The truck is low mileage (~78,000) and in overall great condition, but the frame and some of the components directly attached to it have rust and rot in a way not indicative of the age, consistent maintenance, mileage, and use of the vehicle. Of particular concern and imminent failure is the area near the transmission crossmember and the boxed portion of the frame in the front, that supports the front suspension. The truck was inspected and assesed in ohio by an independent repair business and deemed a safety concern, as the frame is compromised. How have all the other years of Toyota trucks received safety recalls surrounding the inferior steel and treatment used in their frames except for the 2005-2006 Tundra model years?.

I recently purchased the 2005 Tundra I was instructed to take the Tundra to westbury Toyota for inspection and they didnt even took at the truck they claimed according to the VIN is not eligible for any consideration from Toyota north north America the frame has recessive deterioration. We understand the truck doesnt have lifetime warranty but I am disappointed in Toyota's response.

It’s has come to my attention that this is an on going issue with Tundra frames rusting out after being sprayed I inherited this truck from a family friend and the truck is getting to where it’s not drivable for frame issues this needs to be addressed by Toyota ASAP!!.

I own a 2005 Toyota Tundra 4dr. And in January of this year 2022 a recall was sent out on ‘inadequate hardness of ball joint housing’. My Tundra is having ball joint problems meaning skeeking on the front wheels, vibrating until over 55 mph. , and suspension problems. I called a Toyota dealership to get the truck fixed but they told me that back in 2007 the ball joints were already fixed. I shouldn’t be having this problem if the recall just came out. I’m trying to get this problem corrected on my truck without having to pay the $900 bill they want to charge me to fix it. Whst can I do ??.

The frame has rotted to the point the vehicle cannot be driven. Rusted with holes all in it unsafe.

Perforations in frame along seams due to rust isolated to the driver side front frame rail. Toyota is aware of this problem and refuse service and repair.

The frame has several holes in it. Toyota said they did the corrosion prevension on it and said the repair is out of warranty. The sway bar has broken free of the frame and there are several hole and flaking spots on the frame.

Limited service campaign dsd 2004-11006 Tundra frame inspection. I bought an 05 Tundra last year. Called Toyota and they said this recall is over. My frame needs repairing. They are not helping. Do I have any recourse?.

While driving down the road my spare tire mount failed do to rust corrosion causing my spare tire to fall off of my vehicle. Upon inspection the entire rear frame as well as parts of the front are corroded and flaking chunks of metal off. This rusting also affects suspension mounts and the entirety of the rear axle.

The leaf springs have broken and frame is showing serious rust damage. Brake lines were leaking and had to be replaced.

2005 Tundra frame is rusted in many places. Very bad where frame sections meet and now the frame is rusting through the main horizonal frame itself as the attached picture indicates. This has been an ongoing issue for years but is bad enough now that it is not safe and will not pass inspection. I know there was a recall on this frame and I was told it was ok when I brought it in for the recall. I t has been rusting ever sense. We have only purchased Toyotas and Lexus vehicles for the last 20 or more years and this is the third truck rust has totaled. Please help.

Significant frame corrosion in multiple areas to include one area with a hole all the way through the frame rail, and most acutely where the rear leaf spring connects to the frame with only 50% of the contact area appearing to be structurally sound. Dealer states nothing they can do. Two auto restoration shops state the frame is going to fail and cause an accident.

I dont know exactly is the front ball joint or something else but something happen when run and stop the Tundra, all the time hear a noise how to something is broke.

I took this truck into my local Toyota dealer on July 09, 2015 as part of a recall for a frame inspection. The mileage at that time was 295,801. The dealer said the frame was in good shape and applied a corrosion inhibitor as part of the program. In February of this year, (2020) I decided to install new break pads. When I removed the wheel on the driver side, I found a significant hole in the frame and cracking all around the area. In approximately 5 years and 17,000 miles, this developed. I have not driven the truck in the winter for about 8 years as this became a secondary vehicle only for summer project use around the home. I contacted Toyota corporate and they said that there weren't any programs available to remedy the situation and I was basically out of luck. I recently took the trunk to a frame & body shop and was shown much more extensive failure in the frame on both sides. He determined the frame is unrepairable because of the amount of rot and the truck will need a complete new frame. I can't believe that in 5 years driving, averaging 3,400 miles a year that the frame went from good (as the dealer described it) to being undriveable. Toyota new the steel was bad in many of their trucks and SUV;s but has refused to repair all that were affected by the bad steel and lack of protection applied during manufacturing. I have had to pull the truck off the road as it has become unstable and hazardous to drive.

At speeds above 50+ the rear end constantly rumbles and shakes the whole truck. And when pressing the break it does as well. Seat belt locks when trying to put it on. Parking brake doesn't work. Whining and squeaky noise in the rear end. Clunking noise at lower speeds. Engine light is on & won't go off. Tire pressure sensor doesn't work. Rear end seal leak. Driver side window feels like it's gonna fall out. Truck is way too loud and everything is stock. Ac/heat being on makes loud noise.

Significant frame corrosion in multiple areas to include one area with a hole all the way through the frame rail, and most acutely where the rear leaf spring connects to the frame with only 50% of the contact area appearing to be structurally sound. Inspected by Toyota dealership who rated damage as just barely better than unsafe to drive, however not covered under recall. Vehicle has 175k miles on it, and has spent the majority of its life in SC and MD where road salt usage is low. Frequently cleaned undercarriage, and periodic application of corrosion preventative compounds did not alter outcome which implies poor materials and/or manufacturing defects.

The contact owns a 2005 Toyota Tundra. The contact stated while driving at 40 mph, when the front passenger side tire detached and rolled away on the road. The contact stated the front passenger side door and fender hit a curb. The air bags did not deploy. The contact stated he did not sustain any injuries or seek medical attention. A police report was not filed. The vehicle was towed to an independent mechanic and was informed that the lower ball bearing needed to be replaced. The vehicle was not repaired as of yet awaiting the part. The contact called local dealer maita Toyota of sacramento located at 2500 auburn blvd, sacramento, CA 95821, (916) 481-0855 and notified that the vehicle was repaired previously under NHTSA campaign number: 07v013000 (suspension) back in 2007. The manufacturer was not informed of failure. The failure mileage was approximately 330,000.

I own a 2005 Toyota Tundra with just 60,000 miles. In 2014 Toyota was allowed to put a band-aid on a problem that needed a tourniquet - applying a rust converter coating to a frame that, because of their failure to manufacturer it properly, deserved replacing. I was told by Toyota (case number 1912132549) that because the previous owner took the band-aid they were no longer liable until the government forced them via further government safety recall actions to do more. My hope is by writing this that the government can be proactive and solve this safety concern before they have to collect enough death and accident statistics to take notice of this issue. Not only that, I see that Toyota is being offered the same band-aid solution on a number of new models with the same issue - proving that they didn't learn any lesson just how they can get away with actual murder. The result will be more vehicles in 5 years in worse shape due to the lenient reconciliation mandated by the government. Do not put more lives at risk in order to save a multi-billion dollar companies bottom line. The frame which is known to be prone to excessive, premature rust corrosion because the frames were not properly prepared and treated against rust corrosion when they were manufactured should all have to be replaced under this recall to protect american drivers. This excessive rust corrosion compromises the vehicles� safety, stability, and crash-worthiness because important suspension components, engine mounts, transmission mounts, and body mounts anchored to the vehicles� frames are at risk of failure. Do you want this vehicle (picture attached) passing your family on a two-lane highway, because I can tell you there are a lot, and soon to be even more, doing it every day.

On September 30, 2019, my 2005 Toyota Tundra (purchased new in 2004) did not pass inspection due to rust holes on the frame; mileage was 81,147. I looked up VIN number on NHTSA and there is only one recall dated October 2019 not fulfilled for my vehicle. A local dealer investigated my VIN number, and told me there was a d zero d/limited service campaign (expired 2015) regarding rust problems with this vehicle. I was not notified by Toyota about this. I have not moved/changed address since I purchased this vehicle, and I did receive and fulfill the 2016 and 2007 recall notices. I called NHTSA and told the woman on phone about the d0d/lsc and she found it for me under �manufacturer communications�. I have taken good care of it and have all of my service records. I expected it to last and am disappointed Toyota did not notify me. I am requesting NHTSA make these limited service campaigns for vehicles visible with the other recalls. I look forward to hearing back from you and a resolution of this problem.

The frame rusted to the point that it will not pass a state inspection. The brakes would not stop the vehicle when in forward motion, which caused an accident.

I believe my Toyota frame is rusted. The truck has 56,000 miles. The front wheel has a noticeable problem with the camber - it can not be driven safely.

Service bulletin p2445 for secondary air ingection system then notes the frame is corrosion and mounts are braking off.

My 2005 Toyota Tundra was recalled for rust problems, and in 2013 the Toyota dealership applied a coating to the frame which they advised would remedy the problem. On 06/01/18 I noticed I however have holes in my frame near where the suspension attaches, and the frame is not safe for operation on the road. The dealership said they are not liable, and I called Toyota and they said they are not liable and no one will fix the issue. The dealership had the option in 2013 to either spray or replace the frame, they sprayed mine but it was not effective and now I believe the vehicle is a hazard due to holes in the frame. I only have 118,000 miles on the truck, and it has been in my family since being brand new. I believe the frame is defective and Toyota inc. Is not assisting me with fixing the problem, they advised me I need to go talk to a body shop to see if they can weld a piece into the frame.

I was driving my 2005 Toyota Tundra on the interstate. I came upon road work and slowed to the 45 mph speed limit. All of the sudden the truck dropped to the front left with a loud crash. Sparks were flying and I lost control of the vehicle for a brief time. I was able to slow and steer the truck to safety. I got out of the truck to see the front drivers side wheel buckled underneath the truck and major damages to that side of the vehicle. I'm very lucky to have slowed for road work. If I had of been doing interstate speeds of 70 mph I would not have been able to handle the vehicle and could have had severe and fatal consequences. Every day for the prior week or so I noticed the trucks steering being weird (pulling a little to the right side and not being able be steered with the normal ease) and it making a loud squeaking sound when turning.

My 2005 Toyota Tundra's control joints messed up while I was driving.

The main chassis has has rusted and broken.

The contact owns a 2005 Toyota Tundra. While driving various speeds, the contact heard a crushing noise coming from the rear driver side. Once he arrived home, the contact looked underneath the vehicle and noticed that the frame had corroded through the entire chassis on the front driver side. The contact also stated that the front of the chassis dropped below the rear part approximately one inch and a quarter. The vehicle was not diagnosed or repaired. The manufacturer was notified of the failure and informed the contact that they would not assist with the failure. The approximate failure mileage was 82,000.