2004 Toyota Tundra Body & Structure Problems

The contact owns a 2004 Toyota Tundra. The contact stated that the vehicle was Emissions tested, and rust was discovered on the driver’s and passenger’s side subframes. The dealer was notified of the issue, but the vehicle was not repaired. The manufacturer was notified of the failure. The contact related the failure to NHTSA Action Number: PE09049 (Service Brakes, Hydraulic, Tires, Fuel System, Gasoline, Structure). The failure mileage was 72,000.

The contact owns a 2004 Toyota Tundra. The contact stated that after purchasing tires for replacement, the tire technician stated that the subframe was damaged from corrosion to the front frame, the side members, and the rear subframe. The contact was informed that the most severe corrosion was located on the driver's side front subframe behind the wheel well. The subframe was almost fully rusted through. The contact was referred to a welder by the tire shop. The vehicle was not repaired. The manufacturer was informed of the failure and issued a customer complaint report. The failure mileage was approximately 114,000.

Frame rot on the original frame with a recall

The contact owns a 2004 Toyota Tundra. The contact stated that on several occasions, while driving at undisclosed speeds and then parking the vehicle, the contact observed oil leaking from the vehicle. The contact stated that on another occasion, while driving at an undisclosed speed, the check engine warning light illuminated. The vehicle was inspected, and the contact observed corrosion and holes on the frame of the vehicle, and the motor mounts were rusted, causing the engine to run abnormally low. The vehicle was towed to an independent mechanic to be diagnosed, and it was determined that the vehicle was flexing due to the holes throughout the frame of the vehicle. The mechanic was unable to lift the vehicle due to the excessive corrosion. The vehicle was deemed unsafe to drive. The manufacturer was notified of the failure. The failure mileage was approximately 150,000.

The contact owns a 2004 Toyota Tundra. The contact stated that while the vehicle was parked, the contact became aware that the sub frame underneath the vehicle was rusted. The contact was concerned that the sub frame could collapse. The vehicle was taking to the dealer to be inspected. The contact was informed that the sub frame needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure and a case was opened. The failure mileage was 157,000.

2004 Toyota Tundra’s Frame is abnormally rusted. The paint and the mechanical function of the vehicle is pristine however the frame has corroded and rusted egregiously. There was a class action suit a few years back but they failed to notify me of the open recall to replace and even on file there was never any pending notice of such recall for my vehicle although it qualified and I have been the only owner of the vehicle.

I took my truck to a garage for simple tire repair. I had a slow leak. In the process of trying to lift my truck, the technician hear 'crumbling sounds'. They stopped the lift immediately. Upon looking at the my chassis frame, the technicians saw major rust damage. One technician used flashlight to tap against the frame and he poked through it. The technician stated that this was not the first time seeing this problem on this truck model style. I contacted a local dealership. The individual I spoke with at the dealership also confirm rusting issues on the frame of my truck style model. I researched this on the internet to find out multiple complaints concerning the premature rusting of these frames due to poor quality steel and inadequate rust prevention coating. I reached out to my vehicle manufacture "care line". They stated they could not help me. My fear is my frame could break while driving and cause a vehicle accident. The worst frame damage is near the front wheels, both sides. The body, engine, transmission and all other safety components are solid and working well. Side Note: My dad owns a 1992 full size pickup truck (different manufacture). The frame is still solid. My truck is 10 years newer and the frame is falling apart due to manufacture using poor quality steel.

Noise in front end. Inspection reveals rust holes on the frame rail near the sway bar bracket. Multiple areas rusted through.

The contact owns a 2004 Toyota Tundra. The contact stated that while the vehicle was in for the State Inspection, he was informed that the sub frame underneath the front driver's side door was severely corroded. The vehicle was taken to an independent mechanic, and it was determined that the sub frame needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure and referred the contact to the dealer for assistance. The failure mileage was approximately 171,000.

When I was driving, the mount for the brake line dropped and twisted and damaged the steering rod. I drove straight to a mechanic, and he showed me that the frame was rusted out completely, and the truck is not safe to drive.

I have severe frame rot, holes forming in the frame!

Frame is rotting for some reason and I take care of my vehicle. At some point in time it will be very dangerous to drive.

I inherited my father’s Tundra which now only has 95,000 and almost flawless body. As part of the recall for Tundra frames, I took it to the dealer and they wanted nothing to do with the frame replacement and only put on undercoating. This has made it worse. On my last inspection (May) I was told that this truck frame is failing and I won’t be passing another inspection. I called a different dealer in the area and they said they cannot replace the frame now because of the other dealer’s coating. Would it be possible to have Toyota still replace the frame because it’s a safety issue? There is no reason to scrap the truck seeing as the rest of it is fine. Please advise and thank you for reading this!

I had my truck inspected for the frame recall a few years ago. My current mechanic says the frame should not look as bad as it does for the 125k miles it has on it. They have concerns that using a lift on it will damage the frame. This could make it nearly impossible to remove/change the tires. I look at other trucks from ford/Dodge/GM near the same age and I do not see anything similar on the frames. More of a surface rust then flake. The body and engine look great. Suspect while everything looks good the frame will be unable to perform as designed. I have reached out to Toyota and they want me to contact local dealer. I am concerned as recently a brake line failed and I am not sure if this will cascade into a large repair bill due to rusted components.

The frame on my newly purchased 2004 Toyota Tundra is rotted through. The consumer protections Toyota claims to have taken to correct this, in this instance, the application of water seal to the frame in 2014 has trapped moisture and caused extensive corrosion rendering the vehicle unsafe. I have visited multiple Toyota locations received the same message. Toyota claims no responsibility for this course of events leaving consumers in my position with no recourse and with an unsafe vehicle we cannot use and in my case have spent almost eleven thousand dollars on. Where is the responsibility to consumer safety?

The frame of my 2004 Toyota tundra sr5 has a big rutted hole on the bottom of the frame, right under the driver's door side. the hole is about 1.5 ft long and 1 inch with. now I feel unsafe doing anything on the truck since I don't know how big the problem is. these problems Affect brakes, suspension, etc, I see many tundra owners complaining about this problem. I don't know when the previous owner got the truck sprayed at the dealer but it didn't work. I'm very disappointed since it's a nice truck, Toyota should take action on this matter, it is very unsafe for many people on the road. Toyota needs to find a resolution.

2004 Toyota Tundra frame Rusted out should have been changed years ago. Toyota of stamford covered it up says my truck is unsafe to drive. Toyota wont help me please help. Ive tried everything. Little guy like me cant take on Toyota. Toyota will win everytime

The contact owns a 2004 Toyota Tundra. The contact stated that upon taking the vehicle to the dealer for an unknown repair, the contact was informed that the sub-frame underneath the vehicle was severely corroded. The dealer stated that it was too dangerous to go underneath the vehicle to complete the repair. The manufacturer was made aware of the failure but provided no assistance. The approximate failure mileage was 184,000.

TL* THE CONTACT OWNS A 2004 TOYOTA TUNDRA. THE CONTACT STATED THAT AFTER TAKING THE VEHICLE FOR STATE INSPECTION, HE WAS INFORMED THAT THE UNDERCARRIAGE AND SUBFRAME WAS CORRODED AND THAT THE VEHICLE WAS NOT SAFE TO DRIVE. THE CONTACT DROVE THE VEHICLE TO FOWLER TOYOTA OF TULSA (6868 EAST BROKEN ARROW, FRONTAGE ROAD, TULSA, OK 74145) TO BE INSPECTED. THE MECHANIC CONFIRMED THE EXTREME RUST CONDITION AND STATED THAT THE VEHICLE WAS NOT SAFE TO DRIVE. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 156,000.

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.