Problems with 2004 Toyota Tundra STRUCTURE

I noticed the vehicle frame has 4 holes on the frame. the holes are on the passenger side and driver side near the exhaust manifolds. the holes are approximately 2 to 3 inches in length.

Tl* the contact owns a 2004 toyota tundra. the contact detected that the passenger side engine compartment contained a hole and hairline crack. also, the fuel tank was falling apart and the crossmember was rusted. there were no warning indicators illuminated. the vehicle was taken to carbone toyota of bennington (751 n bennington rd, bennington, vt 05201, (802) 440-1854) where it was determined that the frame needed to be replaced. the vehicle was not diagnosed or repaired. the manufacturer was contacted and did not assist. the failure mileage was 222,877.

I have a 2004 toyota tundra limited 4wd in immaculate condition with 100,000 miles. the frame was sprayed with corrosion at a toyota dealer in 2014. the trucks frame is now completely rusted and not safe to drive. i have called toyota about the issue and they do not seem to care. they should have fixed the issue back in 2014 and this wouldn't have happened.

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.

Purchased 2004 tundra new . never received a recall notice on frame. have a popping noise underneath the truck. toyota dealer just called to tell me that my truck would have to be condemned.now i have no trade in , no vehicle. thank you ,toyota.

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 !!!

Popping and snapping when turning or going over bumps in road led to a mechanical inspection. discovered the frame right behind both front wheels is rusted/rotted such that half or more of it is literally gone. the popping/snapping apparently is caused by the frame kinking and moving at the weakened point and front and back sections contacting each other. i fear that the front part of the truck frame with the wheels, engine, and suspension attached could break and cause loss of vehicle control on the highway.

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

2004 toyota tundra fame rust prevents vehicle from passing state safety inspection. never received the "limited service campaign" notifications but toyota will not stand behind their vehicle. "sorry, campaign has expired. we're not responsible for the us mail."

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

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. 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.

2004 toyota tundra. consumer writes in regards to severe rotting on frame. *ld *tr

Tl* the contact owns a 2004 toyota tundra. the contact stated that the frame was rusted, rotted, and the bottom portion developed bubbles. the vehicle was taken to lakewood toyota (1118 ocean avenue rt88, lakewood, nj 08710, 732-364-9000), but was not diagnosed or repaired. the manufacturer was made aware of the failure and no assistance was provided. the failure mileage was 190,000. .*bf *tr

04 tundra had recall done 5/15, toyota chapmanville wv said undercoating was all needed done. tundra in another shop at independent shop, they inform me to make appointment with a toyota dealer to have frame inspected asap, and do not tow anything whatsoever. ball toyota charleston wva refuse to look at, and said nothing they can do, recall has expired, sorry we can't help you.

I received a recall notice and had my vehicle frame inspected in 2014. i was told it was ok and an undercoating was spayed on the frame. on 11-23-2018 i was looking in the engine compartment and noticed a sizable hole in the frame of the vehicle on the passenger side behind the front wheel. i had took it to the dealership and they confirmed the rusted holes on the frame. i was advised it wasn't covered under any current recalls or campaigns and advised to call toyota corporate to ask for assistance. i spoke to a representative and a supervisor and was given a flat no. my vehicle is not covered under any current campaigns or recalls and the repair would be an out of pocket expense. i was informed it is not safe to drive in the cure condition.

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 where it wa discovered that the entire subframe was rusted through. the contact was informed that the vehicle was unsafe to operate. hoselton toyota (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 an 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.

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 frame' i received a letter for recall from toyota on the rusted frame . so i went to my longtime mechanic and he informed me it was bad, he then began to hit parts of the frame with a small hammer and punched a hole through it and than stoped any more hammering. when i checked my recall vin# it does not show up, even though i received letters for it.

On 11/19/2014 i took my tundra to team toyota for the frame recalled because there were corrosion around the frame. team toyota inspected and applied some type of black spray and given me back my truck while the coating was wet. this was done on the recalled warranty. i bought 4 new michelin tires from bj's and have them installed because team toyota didn't have michelin tires my size when their promotions buy 3 get the 4. 6 thousand miles driven, i took my truck back to bj's for tires rotation and was informed that my frame are corrosive and need to be careful. i call toyota today and talk about the issues with the frame and the way it was done by team toyota and was told there isn't anything that they can do. what can i do about the frame problems? pictures that i attached are taken today with my phone.

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

Rear strap supporting the gas tank corroded on one side and bent due to the weight of the tank. this resulted in the strap rubbing against the universal joint of the drive train and making a clicking sound while in motion.

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

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.

Rear cross member that trailer hitch hooks to has a hole that i pushed thru with my finger while showing a neighbor a 3 in, crack in the cross member on the drivers side, and other metal flaking on front of frame. toyota treated frame dec. of 2014. cross member was not treated.toyota corp. or the dealer did not tell me it was unsafe to hook a boat or trailer to the hitch. toyota said they would not do anything to repair the frame per my vin number.

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.

Shift controller assembly bracket (toyota p/n 33501-0c011) has a design defect in that the part is cast without threaded bolt holes, relying on the installation of the screws to cut threads, by the act of installing the part at the factory, the radial outward force that the screw exerts creates a circumferential tensile stress around the hole, and microfractures in the cast aluminum. over time, the microfractures cause failure of the part. when the part has finally broken, unknown to the owner, the vehicle may not fully engage into the park gear, such that the parking pawl does not engage, resulting in the vehicle potentially rolling which can cause property damage, injury, or death. my vehicle was parked, and began to roll as i was exiting the vehicle, and nearly pinned me under the vehicle. i barely escaped serious injury. i have since discovered toyota has developed a revised part (p/n 33501-0c012) apparently to address this dangerous design defect. since owners do not see the part to know its broken (its concealed in the steering column), they will be completely unaware of the danger. toyota should initiate a volutary recall or tsb to inspect the part, and replace it with the newer part if broken or showing evidence of fracture.

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

My 2004 tundra frame is rotting out, and toyota wants nothing to do with it. or to help me..

Tl* the contact owns a 2004 toyota tundra. while driving 55 mph, the frame rods fractured due to excessive rust and corrosion. the contact temporarily lost steering function. the vehicle was not repaired. the manufacturer was made aware of the failure. the failure mileage was 130,000.

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.

Tl* the contact owns a 2004 toyota tundra. the contact received a nhtsa recall notification regarding rust on the vehicle's frame. the vehicle was taken to a dealer to be serviced per the recall, but was informed that the vin was not included; therefore, no recall repairs were completed. the vehicle was later taken in for routine maintenance. the independent mechanic informed the contact that the frame of the vehicle was severely rusted and unsafe to drive. the manufacturer was made aware of the issue and a case was filed. the recall details were not provided. the failure mileage was 118,000.

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 scheduled maintenance. the vehicle could not be repaired because the frame was severely rusted. the contact stated that the vehicle was evaluated by the dealer two and a half years ago where it was diagnosed that the frame was fine. the vehicle was diagnosed a second time and the dealer determined 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 expired. the vehicle was not repaired. the approximate failure mileage was 135,000.

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

This is an ongoing and escalating problem with the rusting of the chassis. i noticed a leak originating from the rear differential. took it to the dealer on 10-20-16 where i was told the fuel tank straps had completely rusted off and nothing was holding the tank. the differential leak was also a result of excessive rust and that the entire rear end would need replaced for $2k. the dealer gave me a rental due to the safety hazard of the fuel tank support straps being completely gone. another $400 dollar repair. the body of my tundra is in very good shape as far as rust goes. the "known" issue of excessive chassis corrosion was addressed by toyota with a "bandaid" recall where they sprayed the chassis with anti corrosive material which i had done. a year later most of this anti corrosive material has flaked off due to the application of the material over the existing rust on the chassis at the time. it is a good thing that the rear differential rusted out when it did because the fuel tank falling out would have been a major safety problem.

Observing excessive frame rust and frame decay. concerned about structural safety based on the significant frame degredation. *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!

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

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.

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.

Rusted rear differential. rusted frame at front right sway bar. can't pass inspection. seems to be a common problem just like the 2003 model. i still have payments on this vehicle i can't drive.

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. rear differential is completely rusted and leaking fluid. problem also with catalytic converters.

Tl* the contact owns a 2004 toyota tundra. the contact stated that the vehicle was previously serviced per a nhtsa campaign related to the frame rusting; however, the failure recurred. the manufacturer was not notified of the failure. the failure mileage was 109,265. the vin and nhtsa campaign number were not available.