Problems with 2004 Toyota Tundra SUSPENSION

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.

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

Rear end failure due to rust problem known to toyota. they replaced frame with no consideration for safety of passengers. drive train locked up while driving down highway. found bell housing on rear end rusted through allowing fluid to run out! dangerous. toyota should take responsibility for bad product! welded bell housing, cannot repair. please help!!!! almost caused wreck! cars swerved to avoid colision.

My front ( passenger ) right wheel assembly rusted away from 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 got a recall notice on my vehicle a few months back about airbags so i looked it up on this site and it says i have no recalls on my vehicle the airbag light has been on since i've got the truck but i thought it was a electrical issue but now after receiving the recall notice and reading the recall it really has me worried for the safety of me my wife and my children i would really like some information on the airbag recall and the suspension recall my vehicle has a lot of the same issues as the recall points out

Frame of the truck is completely rusted. the upper arm bolts are not able to be connected to the frame as the frame is completely rusted. the rest of the frame is being evaluated at this time. called toyota and they say that the this truck is not part of the re-call, but they will not do anything until the national highway transportation tells them they have to do extend the recall into other years of the tundras. as of right now it only includes the 2007-2008 trucks.

Tl* the contact owns a 2004 toyota tundra. the contact took the vehicle to creek side auto mechanic shop for inspection where the technician found severe corrosion. toyota of grand rapids was contacted and referred the contact to toyota usa. the manufacturer was notified of the failure. the failure mileage was 90,000. updated 08/29/17*lj *cn

Tl* the contact owns a 2004 toyota tundra. while driving approximately 65 mph, the vehicle dropped to the left twice. during the second drop, the contact noticed that metal to metal was rubbing on the lower ball joint. the contact coasted to the side of the road and noticed that the lower control arm was resting on the wheel. the vehicle was taken to the dealer where it was diagnosed that the ball joint separated and damaged the front suspension and needed to be replaced. the vehicle was not repaired. the vin was included in nhtsa campaign number: 07v013000 (suspension). the manufacturer was made aware of the failure. the approximate failure mileage was 150,000.

Tl* the contact owns a 2004 toyota tundra. while driving 65 mph, the steering became difficult to operate. the contact stated that the front driver side suspension fractured, which caused the wheel to buckle under the wheel well. the vehicle was towed to the dealer to be diagnosed. the contact was informed that the lower ball joint loosened, which caused the failure. the vehicle was not repaired. the vehicle was included in nhtsa campaign number: 07v013000 (suspension). the manufacturer was notified of the failure. the approximate failure mileage was 150,000.

Driving at low speed on city street. front left wheel collapsed due to broken ball joint. all wheels had been replaced a couple of days prior by tire dealer. vehicle had a recall in 2005 for ball joints which was completed at 75k miles on march, 2007. current mileage is 299,525 miles on that replacement. i do not think many owners keep vehicle for that number of miles. however vehicle is in good condition and potential seems to exist for bearing failure. i do not think that wheel replacement was the cause though something may have loosened during wheel installation. i did not file a police report or insurance claim. no other vehicle was involved. original recall number: 05v225000, may 17, 2005.

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. *tr

Noticed last week the frame of my truck was rotting on my driveway! upon further inspection i discover large holes completely through my box frame. after cleaning out almost 5lbs of rotted frame i can no longer put my family and friends in this vehicle. that would make me irresponsible and negligent like the manufacturer! i purchased this vehicle in jan 2015 when it only appeared to be a surface rust issue. recieved notice of the limited service campaign the month after it was over so toyota refused to even inspect it. now this year i have holes you can put your hand through and toyota still refuses the frame is bad. in the limited service campaign toyota says "the condition is unrelated to and separate from normal surface rust". how could this be s voluntary limited service campaign and not a mandatory safety recall?? sounds like a loophole created by design!

Tl* the contact owns a 2004 toyota tundra. the contact stated that there was an abnormal noise coming from the vehicle. it was taken to a dealer for a front end alignment and the mechanic indicated that the sway bar fractured from the frame. in addition, the mechanic stated that there was extensive rust on the sway bar and frame. the dealer indicated that the sway bar and the frame needed to be replaced. the manufacturer was notified of the failure and indicated that there was no recall to address the repair. the failure mileage was not available.

I took my 2004 toyota tundra to a local service center because i thought it needed shock absorbers. once on the lift we found the entire rear section was completely rusted out with several major parts just hanging from the frame. toyota claims they sent recalls in 2015 however i did not get them. i did receive a very recent recall for an air bag and front coil springs, within a week the truck was taken in for the recall. at no time was i informed of the dangerous issue of the rear suspension. i called toyota to discuss the matter and was told they would not do anything to correct the problems. i am very lucky i did not have an accident because the rear components could have failed at any time while i was driving. toyota will not accept any responsibility and they were quite rude when we spoke. please inform me of any recourse i may have, the cost to repair my truck is in excess of $4,000. i am retired with a limited income and depend on my truck to pickup farm supplies at my home. i live in md and rely on the truck when it snows or the roads are icy. toyota clearly has a past of not taking responsibility, they knew or should have known the quality of the metal materials were inferior. they waited 11 years before they recalled some of their trucks. i do not wish to be rude however, i firmly believe toyota has no regard for the quality of their product or the problems associated with their poor engineering. it is my hope you can help me with this matter or direct me to someone if can help me. thank you for your consideration. [xxx] telephone [xxx]. if you will provide your address i will sent photos. sorry i do not know how to upload them to you. the date the truck was taken to the service center is 5/6/16, it is still there as it cannot be driven. information redacted pursuant to the freedom of information act (foia), 5 u.s.c. 552(b)(6). *tr

Frame rot and rust. the gas tank fell out from under the truck while driving down the road (city street), the brackets holding the tank completely rusted in two. this happen after the frame protect spray was applied to the truck by the dealer 2 years ago. the frame is a mess, i'm worried about driving this truck because of it but i also can't trade it in because no one wants it. i'm happy to send pictures if needed.

Tl* the contact owns a 2004 toyota tundra. the contact received notification of nhtsa campaign numbers: 05v254000 (air bags), 07v013000 ( suspension), and 15v286000 (air bags); however, the part to do the repair was unavailable. the manufacturer exceeded a reasonable amount of time for the recall repair. the manufacturer was made aware of the issue. the contact had not experienced a failure.

Frame rusted through unsafe to drive. received very first letter in july about a recall. it is september 21, 2015 and the recall ended august 31, 2015.

The entire frame and under side of the truck to include brackets, cables, fittings, and exhaust are so rusted and flaking off that i'm concerned that the truck may break apart driving down the road. i bought the truck used from lowe toyota in warner robins, ga and had no idea that the truck was a rusted out disaster waiting for a place to happen !!

Left front ball joint on 2004 toyota tundra 4wd failed and pulled out of socket with no warning (e.g. loose steering, noise, or vibration) at approx. 2 mph in parking lot. this caused the left axle to pull out and hit the ground damaging the splines. there was an earlier recall for this same problem and the recall service was performed by installing a "new" replacement ball joint in 2009. luckily we had just exited a freeway traveling at 65 mph. since there was no "accident" and no "comprehensive" damages, the auto insurance did not cover any of the $1,200 damage or $200 rental car expense. *tr

I went over a speed bump in a parking lot and the front drivers side wheel fell off and was wedged under the fender. the mechanic and tow truck drive said that the lower ball joint failed. *tr

Tl* the contact owns a 2004 toyota tundra. the contact stated that while driving at 15 mph, the front driver side wheel detached without warning. the vehicle was towed to a dealer. the dealer diagnosed that the ball joint needed to be replaced. the vehicle was not repaired. the manufacturer was made aware of the failure. the failure mileage was 103,000.

Frame rusted, crack and holes are larger than 7/16 inch through right front inside behind motor mount. vehicle is stationary, parked after toyota employee verbally stated unsafe for road trip but could be used around town. 11/11/17 sparks toyota frame recall, corrosion resistant compound applied by bristol toyota on 11/2014, after bringing it in for recall of frame replacement. contacted toyota corporate 9/20/2017 and they stated they could do nothing for me, contact nhtsa for safety issues.

Rust all over the undertruck, even the catalytic converter is rusted. i was part of that recall and the dealer is going to spray the frame to stop the corrosion. can the corrosion process ends with the spraying? *tr

I have recently received a frame recall notice due to excessive corrosion which i addressed at the local dealership. i was informed that the rust had not perforated the frame and that it would be treated to prevent further rusting. when i picked up the truck at the dealership the associate advised me that the recall was done and that a full safety inspection was completed which revealed no other problems. when i returned home i looked under the truck to inspect the frame and noticed that both sway bar links had corroded and broken off . i also subsequently took the vehicle to an alignment shop because i noticed the steering wheel was not straight and was told by the shop that the truck could not be aligned. i was told that the vehicle was very dangerous to drive and to bring it to the dealership immediately which i did. the dealership service department discovered that the steering shaft coupling was so corroded that they needed to replace it and do a wheel alignment. i am concerned that this may become a common safety issue with the tundra which seems susceptible to excessive rusting and am requesting that this issue is investigated an a recall issued if necessary. *tr

I am disabled and i keep receiving recall notices about airbags, and frame recalls from toyota, but the local dealers tell me that they do not have the parts to fix them. i am unable to carry anyone in the passenger seat because of safety advisories and this is affecting the value of my vehicle, and risk of injury to myself and any passengers i may carry, and insurance coverage because of the recall notifications. i suffered diligently to pay for this vehicle and now i find it's an unsafe piece of junk that i cannot use. i really want this vehicle fixed or replaced with one that is not unsafe.

Tl*the contact owns a 2004 toyota tundra. the contact stated that the vehicle was severely corroded and affected the power train, rear end, wheel, axle and belt housing. the contact received a notice for nhtsa campaign number: pe09049 (fuel system, gasoline , service brakes, hydraulic , structure , tires) and the dealer was made aware of the failure. the manufacturer was not made aware of the failure. the vehicle was not repaired. the failure mileage was 86,000.

Frame recall- my 2004 tundra was recalled for the frame rusting out. toyota deemed that a new frame was not needed and did the crc treatment which is absolute junk and only causes the frame to rust even worse. i want a new frame installed by toyata and any other rusty part- all should be replaced free of charge

Had truck in for oil change whole frame, drive shaft parking brake cable is rusting through. *tt

Noticed that vehicle was pulling to left. check alignment ok. noticed that sway bar link had snapped due to corrosion. replaced with toyota part and condition corrected. *tr

Excessive rust on frame, under body, and suspension. rear axle / differential has large flaking rust so bad that it will not hold lubricant. filed complaint with toyota on 11/13/2013 and was given a case # and turned in photos at local toyota dealer in early december 2013. contacted toyota in january 2014 and was told that a recall was going to be issued but it would cover frame only and no other components would be covered for rust. i personally took it upon myself not to drive this vehicle because i feel it is unsafe and not road worthy due to rust. i also feel that a company that i had a lot of respect for because of their reputation for quality and safety has let me down. vehicle has been parked since 11/13/2013 and will not be driven until properly repaired or replaced. *tr

I recently noticed a leak under the rear of the vehicle. upon inspection, the differential was found to be rusted right through and leaking. i examined the frame as well and noticed severe rusting in various places on the frame. i never received a notice of recall on the frame. apparently there is not only frame damage to many tundras, but also to necessary working parts. i have never had an axle rot out on any of my cars and because of the inability to simply repair a seal, the entire axle will need replacing? seems a bit extreme. i like the tundra and will base my decision to remain a customer on how i'm treated in the recall appointment. *tr

There is extensive corrosion damage to all metal fittings and metal fuel and hydraulic lines. the rear axle is severely corroded and leaking oil through the casting requiring replacement. there is a fuel line failure next to the exhaust manifold. the corrosion damage to the steering system fittings requires replacement of the rack assembly although the system operates properly. there is corrosion damage to many of the suspension connection points to the frame including rear springs. dealer deems the vehicle unsafe in it's current condition and recommends it be sold for salvage. there is little to no corrosion damage to the body that can be seen from a visual underside inspection and vehicle looks in excellent condition from the outside. vehicle was dealer maintained per the manufacturer's maintenance schedule.

While driving the spare tire fell off of the truck due to a badly rusted spare tire wench, as i looked under the truck to see if their was any other damage i noticed a lot of rust on the frame. most notably around the suspension. *tr

I took my truck to the toyota dealer because of a noise in the front end. it turns out the frame at the attachment points for the stabilization bar was badly rusted. there are rust holes in the frame and the attachment point on the left side had rusted free of the frame and the other side is not to far behind. toyota has a history of rusted frames but according to the vin number it is not part of the current recalls. i was told sorry we can't fix it. this is not right!!!! can you help. *tr

Massive generalized rust under vehicle. this is affecting the frame, suspension, all lines, exhaust, all metal fittings, wheels, brakes, spare tire. my mechanic does not know how to proceed and suggested we no longer drive this vehicle. toyota dealer said this is not included in the rust recall which is in effect for tundra trucks exactly like this one , but off by a couple months by manufacturing date. our toyota dealer did not have a suggestion or answer for how to fix this, other than to ask if we were interested in buying a new car. we bought this truck new and have taken excellent care of it. the inside and upper body looks new. *tr

Brought my truck in for an oil change. i was called at work by my garage, they told me the truck was unsafe to drive due to several holes and cracks in the frame due to severe rust. i brought the truck to the dealer i purchased it from and they agreed that the truck was not drivable. toyota has said the 04 model is not part of the recall, and i appear to be in limbo. it has been 3 weeks and this issue is still unresolved. the only certainty is that the truck will need many new frame components for it to be road worthy again. *tr

Frame is badly rusted in many areas including where suspension and brake components mount. i am concerned a major failure could lead to injury to myself or a member of my family. i understand there was a recall for 2000-2003 tundras for the same issue but my 2004 was not included in the recall. *tr

Brought vehicle in for new muffler and tailpipe. mechanic showed me a leaky rear seal because the metal cover was rusting through. also showed me main frame and suspension points which are , in his words, "like rust holding hands". *tr

6/13/13 vehicle did not pass inspection major frame perforation toyota performed limited frame replacement at their cost after much discussion . not all severely rusted parts were replaced only the major assembly mounting piece items that were disassembled and couldn't be reused were replaced. no sub pieces of the major assembly were replaced. if the were rusted they were reinstalled. 8/4/14 vehicle did not pass inspection major rust failure deformation and leaking of steering rack housing that was severely rusted and not replaced when frame was replaced. rack was replaced by owner at owners expense. 4/15/15 rear differential housing rust thru and housing failure. housing was severely corroded when frame was replaced. owner was informed it was not part of the frame replacement . toyota does not have any recall bulletin issued despite the numerous complaints found on the internet. replacement will be at owners expense. brake backing plates and axle mounting hardware that were severely corroded when frame was replaced are not salvageable and will require replacement as well in order to replace the rear axle housing. *tr

While driving on freeway at approx. 50-55 mph, the front left side suddenly jolted downward, sparks and smoke were viewed by both side view and rear view mirrors, i slowly applied brakes thinking it was only a blow out but from the grinding metal against cement sound, i realized it was much worse than a blow out.when finally coming to a complete stop, i saw the whole wheel completely sheared from the front suspension, fortunately, the wheel lodged itself inside the wheel well and the running board on the driver side door. it could have easily gone underneath and caused the vehicle to flip over or even into other vehicle's on road. fortunately, no one else or other vehicles were involved. after insurance company adjuster inspected they determined it to be totaled. i find this extremely upsetting, do i have any recourse? there could have easily been two fatalities. please help!!! i believe after reviewing other incidents like this, there should have been some type of responsibility from toyota. i had no idea there were so many suspension issues with this vehicle... the insurance will not give me enough to offset the loss i incurred. *tr

*the rear differential and brake housing left and right are rotting from the outside. large parts of the differential housing are already missing! *the front transfer case and transmission are perfect! *the entire rear trans-axle is rotting from the outside. *the emergency brake adjustment turnbuckle is rotting. *structural mounts for the emergency brake are rotted. *the steel in the frame and most factory welds are de-laminating. *brackets holding the brake line and junctions are rotting. *capture plate and hardware holding spare tire in place are rotted. i will need a cutting torch to remove the spare tire. i have excellent photos to send. respectfully, *tr

2004 toyota tundra worse than 2003 for metal fatigue. front of rear differential is flaking apart. tension adjuster for emergency brake is disintegrating. adjustment bolts are seized. spare tire attachment is flaking apart. please help. *tr

2004 toyota tundra taken in for service on 05/18/13. well cared for vehicle and serviced faithfully at every interval.told by service manager that the frame has a hole in it.this is a known problem by toyota. frame is very rusty and was part of a problem toyota had with a bad batch of metal used for frames.service manager could offer no relief for this problem and referred me to toyota customer care. customer care complaint number [xxx]. customer care advised they could do nothing about this and basically have a nice day. service manager advised that i should be careful when going over bumps. what should be a 14 to 16 thousand dollar vehicle is now worth nothing. shame on toyota for selling faulty and unsafe equipment. accident waiting to happen. information redacted pursuant to the freedom of information act (foia), 5 u.s.c. 552(b)(6). *tr

Frame rotted through. dealer stated( approx) 75 percent of frame where swaybar was welded to frame is gone..swaybar is rotted off passenger side frame. advised not to drive anymore. took to dealer as requested by toyota motor corporation. they took pictures and sent them to toyota representative. *tr

Tl* the contact owns a 2004 toyota tundra. the contact stated that while driving approximately 35 mph, the lower front ball joint separated from the knuckle and caused him to lose control of the vehicle. the vehicle was towed to the dealer and was not diagnosed. the dealer stated that the vehicle already was repaired under nhtsa campaign number: 07v013000 (suspension). the manufacturer was made aware of the failure. the vehicle was not repaired. the approximate failure and current mileage was 189,000.

noticed extreme rust on frame and other metal parts flaking and falling off. condition appears unsafe to drive. tr

Tl* the contact owns 2004 toyota tundra. the contact stated that while driving 35 mph, the vehicle swerved to the right and the driver's side wheel detached from the vehicle. the vehicle was towed to a mechanic, who inspected the failure and advised the contact that the upper and lower ball joints snapped, causing the tires to collapse inward and under the vehicle. in addition, the front axle was found to be fractured. the mechanic replaced the lower ball joints, control arm and the axle. the manufacturer was notified and advised the contact that the vehicle was included in and repaired under nhtsa campaign id number: 07v01300 (suspension: front: control arm: lower ball joint). the manufacturer offered no assistance. the failure mileage was 263,000.

Tl* the contact owns a 2004 toyota tundra. the contact stated that oil was leaking from under the vehicle. the contact took the vehicle to a local mechanic where the mechanic stated that the rear differential house exhibited excessive rust. the mechanic also advised the contact that the vehicle was unsafe to drive. the contact called the manufacturer regarding the excessive rust issue however, the manufacturer provided no assistance. the failure mileage was 62,000.

Catalytic converter failed at 55,023 miles and was replaced under warranty. the same catalytic converter failed again at 110,000 miles and when i went to a dealer was told that it wasn't under warranty and that i would have to pay $1200.00 for the part alone and labor would be extra. i also told the dealer that the high rear brake light housing was melting from the heat of the lights. they did nothing. the frame is rusting badly and is becoming a safety hazard. i called toyota customer service and they said there was no recall for any of these items and there was nothing they could do. "adaptive equipment" is listed as a choice under "affected parts". how about explaining exactly what is the definition of "adaptive equipment"? *tr