2002 Toyota Tacoma Body & structure Problems

Found hole in frame (chassis)

NHTSA ID

11620763

Incident

Oct 4, 2024

The contact's daughter owns a 2002 Toyota Tacoma. The contact stated that several independent mechanics and an auto body repair shop had informed her that there was a hole in the subframe, and the subframe was significantly corroded. The vehicle was taken to the dealer who informed the contact that the vehicle was unsafe to drive. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was approximately 138,000.

NHTSA ID

11542694

Incident

Mar 5, 2023

Mileage

138,000 mi

I went to get my 02 tacoma tires balanced and was called and told that where the frame was cracked. Upon inspecting it myself the crack is where the manufacturer welded the frame together. I'm the 3rd owner of this vehicle and there original owner didn't get frame warranty recall done. Which led to it running out. Now Toyota corporate has a frame case number ([XXX]) and was told that there's nothing that could be done until enough complaints about this case number reaches a certain number then they'll look into it. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11536923

Incident

Aug 3, 2023

The frame has prematurely rusted out causing a driving hazard.

NHTSA ID

11506859

Incident

Feb 12, 2023

The truck frame has completely rusted out and has snapped in half. Leaving my truck undriveable. Toyota had an extended warranty but only if you followed exact criteria. This is a big safter issue that should be recalled

NHTSA ID

11431698

Incident

Sep 3, 2021

Truck frame is rusted to the point the the vehicle is not usable. The problem has been confirmed by a local independent service center. The vehicle has not been inspected by the manufacturer. The first symptom was that the right rear shock became detached from the frame. When I brought the vehicle in to have the shock repaired they stated that there was not enough frame left in that area to re-attach the shock.

NHTSA ID

11427105

Incident

Jan 1, 2021

Truck was taken to dealer about 5 years ago or less for underbody spray and frame inspection "recall". Truck was cleared as safe. Today, Tire shop informs me frame is unsafe to lift the car by, and proceeded to put his hand through the frame to show the severity of the issue. So I take the truck to my local dealer and ask them what can be done about it. They inform me that, this "program" ended in 2016. I read that 10mm holes in frame would issue a frame/car recall. There is no way there wasn't an issue less than 5 years ago. I believe this is negligence of the dealer in keeping people safe in this vehicle and on the highway.

NHTSA ID

11419771

Incident

Jun 5, 2021

The chassis of the vehicle is corroded, metal is exposed. Shocks bracket seems like it might break off. Concerned that vehicle will fail on the road.

NHTSA ID

11419262

Incident

May 24, 2021

FRAME RUSTING

NHTSA ID

11388434

Incident

Jan 15, 2020

MY FRAME IN MY 2002 TACOMA IS ALMOST FULLY RUSTED . I CONTACTED TOYOTA AND THEY ARE NOT WILLING TO HELP EVEN THOUGH THEY KNOW THAT THEIR TRUCKS ARE RUSTING AND THAT THERE WAS A PREVIOUS RECALL SET TO REPLACE THE FRAME. SINCE I JUST GOT THIS TRUCK FORM SOMEONE, I HAD NO IDEA OF THE RECALL AND OF THE RUST . THE CAR IS NO LONGER SAFE TO DRIVE AT THIS POINT SINCE IT IS ABOUT TO BREAK IN HALF .

NHTSA ID

11377833

Incident

Dec 1, 2020

THERE WAS A RECALL ON THE FRAME IN 2010 AND THEY SAID UNDERCOATING WOULD PROTECT THAT HOWEVER NOW THE FRAME IS RUSTED AND NOT SAFE TO DRIVE IF I GET IN AN ACCIDENT IT WILL FAIL. IT ONLY HAS 90,000 MILES ON IT AND TOYOTA IS REFUSING TO DO ANYTHING ABOUT IT. I FEEL THEY SHOULD HAVE A WARRANTY ON THE FRAME.

NHTSA ID

11360865

Incident

Sep 22, 2020

Mileage

90,000 mi

TL* THE CONTACT OWNS A 2002 TOYOTA TACOMA. THE CONTACT STATED THAT AN INDEPENDENT MECHANIC INSPECTED HER VEHICLE AND DISCOVERED SEVERE CORROSION THROUGHOUT THE ENTIRE UNDERCARRIAGE. THE CONTACT SPOKE WITH MARKQUART TOYOTA (1844 COMMERCIAL BLVD, CHIPPEWA FALLS, WI 54729) WHO INFORMED HER THAT THERE WERE NO RECALLS ON THE VEHICLE. THE CONTACT THEN CALLED THE MANUFACTURER WHO WAS NOTIFIED OF THE FAILURE AND DISREGARDED HER CONCERN WITH THE CORROSION. THE MANUFACTURER SUGGESTED THE VEHICLE BE SOLD AND OFFERED NO FURTHER ASSISTANCE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 32,021.

NHTSA ID

11354404

Incident

Sep 8, 2020

Mileage

32,021 mi

TL* THE CONTACT OWNS A 2002 TOYOTA TACOMA. THE CONTACT STATED THAT WHILE HAVING A ROUTINE CHECK ON THE VEHICLE BY AN INDEPENDENT MECHANIC, THE TECHNICIAN BECAME AWARE THAT THE REAR SUBFRAME WAS SEVERELY RUSTED. A DEALER WAS NOT CONTACTED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 190,000.

NHTSA ID

11322942

Incident

Apr 23, 2020

Mileage

190,000 mi

I HAVE A 2002 TACOMA THAT WAS PART OF THE FRAME PERFORATION RECALL. HOWEVER, I DID NOT GET A FRAME REPLACEMENT. THE "FIX" WAS TO APPLY A GEL OVER THE RUST ON THE FRAME, WHICH, SUBSEQUENTLY, ALL FELL OFF THE FRAME ONTO MY DRIVEWAY. RECENTLY, I TOOK MY TRUCK INTO THE DEALERSHIP FOR A 4WD REPAIR AND WAS TOLD THAT MY "FRAME WAS SHOT" AND THE TRUCK WAS "UNSAFE TO DRIVE", DUE TO THAT. AND IF THEY LIFTED MY TRUCK TO DO THE REPAIR, IT MIGHT "CRUSH MY FRAME". I EXPRESSED MY DISPLEASURE FOR THE RECALL FIX AND HAD THEM DO AN ESTIMATE ON THE 4WD REPAIR. THEY CAME BACK WITH AN OUTRAGEOUS NUMBER, AS IF THEY DID NOT WANT TO DO THE WORK. I HAVE SINCE CONTACTED INDEPENDENT REPAIR SHOPS AND NO ONE WILL TOUCH IT. *SO, I HAVE A TRUCK NO ONE WILL REPAIR, I CAN'T SELL IT, I CAN'T TRADE IT IN...AND I CAN'T DRIVE IT. IT HAS NO WORTH.ONE OF MY LEAF SPRINGS HAS RUSTED AND BROKEN, TOO. THE TRUCK HAS 215K AND IS IN GOOD CONDITION OTHER THAN RUST. THE ENGINE WILL GO 500K. I SEE RECALLS ON THE FRAME AND LEAF SPRING FOR OTHER MODEL YEARS, BUT THE 2002 SEEMS TO NOT FALL INTO ANY OF THEM. I DON'T EXPECT A NEW FRAME, BUT ASSISTANCE IN OBTAINING A SIMILAR TRUCK AT A REASONABLE PRICE OR OTHER FAIR SOLUTION MAY BE A CONSIDERATION.

NHTSA ID

11281389

Incident

Nov 13, 2019

Mileage

215,325 mi

FRAME FAILURE DUE TO CORROSION: TOYOTA HAD PLACED A "WARRANTY ENHANCEMENT" TO REPLACE THE FRAMES BECAUSE THEY WEREN'T TREATED FOR CORROSION BUT WITH AN ENHANCEMENT, IT EXPIRES AND DID SO IN 2017. I JUST BOUGHT THE TRUCK AND LEARNED THEY HAVE A SAFETY RECALL FOR CORROSION OF THE SPARE WHEEL COMPARTMENT. THIS IS THE SAME ISSUE. WHY IS THE FRAME NOT A SAFETY RECALL?? I HAVE HUGE HOLES AND LARGE CRACKS ALONG MUCH OF THE FRAME AND MY MECHANIC TELLS ME IT'S UNSAFE TO DRIVE. MY FINGERS GO THROUGH THE SIDE OF THE FRAME! MY MECHANIC TELLS ME BASED ON THE LOCATION OF THE CORROSION IN THE FRONT OF THE TRUCK, THE ENTIRE ENGINE IS IN DANGER OF FALLING OUT!! LOOKING ON THE INTERNET, THIS IS A HUGE SAFETY ISSUE FOR TOYOTA TRUCKS FOR 2002 AND BEYOND. FOR MANY YEARS THIS HASN'T BEEN ADDRESSED. THE GOV NEEDS TO DEMAND A SAFETY RECALL FOR THIS TRUCK AND ALL THE OTHERS AFFECTED.

NHTSA ID

11256676

Incident

Sep 19, 2019

Mileage

155,000 mi

MECHANIC TOLD ME THAT MY FRAME WAS RUSTED THROUGH. HE COULD PUT HIS FIST THROUGH A HOLE IN THE FRAME AND RECOMMENDED I CALL A DEALER TO SEE IF THIS WAS ON A RECALL LIST. WHEN I CALLED AND GAVE THEM THE VIN, THEY SAID NO IT IS NOT A RECALL. WHAT CAN I DO? ESPECIALLY IF I CANNOT AFFORD ANOTHER VEHICLE!

NHTSA ID

11256194

Incident

Sep 17, 2019

Mileage

120,500 mi

TL* THE CONTACT OWNS A 2002 TOYOTA TACOMA. WHILE THE VEHICLE WAS PARKED, THE CONTACT NOTICED THAT THE REAR PASSENGER SIDE WAS LOWER THAN THE OTHER SIDE. THE CONTACT MANAGED TO DRIVE THE VEHICLE TO JEFF WYLER TOYOTA OF CLARKSVILLE (808 E LEWIS AND CLARK PKWY, CLARKSVILLE, IN 47129, (812) 284-2277) WHERE IT WAS DIAGNOSED THAT THE REAR FRAME NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND INFORMED THE CONTACT THAT THE VIN WAS NOT INCLUDED IN A RECALL. THE FAILURE MILEAGE WAS APPROXIMATELY 305,000.

NHTSA ID

11232072

Incident

Jul 15, 2019

Mileage

305,000 mi

TL* THE CONTACT OWNS A 2002 TOYOTA TACOMA. WHEN THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC FOR AN ALTERNATOR AND BATTERY CHANGE, THE TECHNICIAN STATED THAT THE FRAME WAS COMPLETELY CORRODED AND THE VEHICLE WAS UNSAFE TO DRIVE. THE CONTACT ALSO STATED THAT THE FUEL TANK COVER OFTEN POPPED OPEN WITHOUT WARNING. THE CONTACT STATED THAT HE RECEIVED A RECALL NOTIFICATION FOR NHTSA CAMPAIGN NUMBER: 12V542000 (TIRES). THE VEHICLE WAS TAKEN TO BILL WALSH TOYOTA (815-768-1962, LOCATED AT 4000 N COLUMBUS STREET, OTTAWA, IL 61350) WHERE THE FRAME WAS COATED. THE DEALER STATED THAT THE WARRANTY WAS EXPIRED. THE CONTACT STATED THAT THERE WAS NO REMINDER ABOUT THE WARRANTY EXPIRATION. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND STATED THAT THE RECALL REPAIR WAS PERFORMED AND THAT THE WARRANTY EXPIRED. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS APPROXIMATELY 124,000.

NHTSA ID

11230717

Incident

Jul 9, 2019

Mileage

124,000 mi

TL* THE CONTACT OWNS A 2002 TOYOTA TACOMA. THE CONTACT STATED THAT THERE WAS EXTENSIVE RUST AND CORROSION ON THE CHASSIS AND THE FRAME HAD CRACKS ON THE PASSENGER SIDE FROM THE FRONT TO THE REAR. ELMHURST TOYOTA (440 W LAKE ST, ELMHURST, IL 60126, (630) 279-2160) INDICATED THAT THE VEHICLE WAS NOT SAFE TO DRIVE AND THAT THE ENTIRE FRAME AND CHASSIS NEEDED TO BE REPLACED. THE DEALER AND MANUFACTURER INDICATED THAT THERE WAS NO RECALL CAMPAIGN TO REPAIR THE VEHICLE. THE FAILURE MILEAGE WAS NOT AVAILABLE.

NHTSA ID

11218136

Incident

Jun 5, 2019

FRAME RUST RECALL, NOT TAKEN CARE OF IN 2010 WHEN I TOOK INTO HEISER TOYOTA IN MILWAUKEE WI. NOW WE NEED IT TAKEN CARE OF, THIS IS A SAFETY ISSUE AND BOTH TOYOTA AND HEISER REFUSE TO TAKE CARE OF.

NHTSA ID

11217649

Incident

Jun 17, 2010

Mileage

232,000 mi

THE FRAME WAS COATED WITH AN ANTI RUST COATING DURING THE MANUFACTURER RECALL THAT LASTED UNTIL 2017 NOW THE THE METAL IS BECOMING POROUS AND UPON SLIGHTLY TAPPING THE FRAME ONE CAN POKE HOLES IN THE FRAME WITH A PENCIL. THE TRUCK HAS BECOME UNSAFE TO DRIVE. UPON TAKING IT MY LOCAL TOYOTA DEALER WILLIS TOYOTA OF TWIN FALLS IDAHO IN 2016 AND 2017 THEY PERFORMED A POORLY EXECUTED INSPECTION JUST TO AVOID REPAIRING THE ISSUE. THEY TOLD ME BOTH TIMES THE FRAME WAS FINE WHEN IT CLEARLY WAS NOT. THIS TRUCK HAS ONLY 110K MILES ON IT BUT IS SLOWLY BECOMING A PILE OF RUST. HOW CAN A VEHICLE THAT IS JUST 16 YEARS OLD BE SO RUSTED. TOYOTA IS OF NO HELP AFTER REPEATED CALLS

NHTSA ID

11206373

Incident

Aug 10, 2016

I RECENTLY TOOK MY CAR TO MY MECHANIC AND HE INFORMED ME OF A RECALL FOR MY CAR MADE DUE TO THE ROTTING OF THE FRAME. I'VE HAD MY DAUGHTER CALL TOYOTA, WHO'S INFORMED HER THAT MAILS WERE SENT TO MY HOME ABOUT THE RECALL, WHICH I HAVE NEVER RECEIVED. I FEEL THE CONDITION OF THE FRAME IN MY CAR IS A VERY DANGEROUS HAZARD AND I AM NOT ABLE TO USE THIS VEHICLE AFRAID OF WHAT MIGHT HAPPEN.

NHTSA ID

11186926

Incident

Mar 14, 2019

FRAME IS RUSTING REAL BAD AND FALLING APART.CALLED TOYOTA AND DEALER AND THEY SAID THERE IS NOTHING THEY CAN DO. THERE IS A SUBSTANTIAL CRACKING AND BREAKING APART ON THE FRAME I READ ONLINE THIS IS A KNOWN ISSUE AND THERE IS PROBLEMS WITH A LOT OF TACOMA'S AND LIKE TRUCKS. BUT NO ONE WANTS TO TAKE OWNERSHIP OF THE PROBLEM. EVERYWHERE ELSE ON THE FRAME IS LITTLE RUSTY GIVEN THE AGE OF THE TRUCK BUT IN ONE SPOT IT IS ABSOLUTELY HORRIBLE AND SCARY. I DON'T KNOW WHAT ELSE TO DO OR WHERE ELSE TO TURN.

NHTSA ID

11163301

Incident

Mar 1, 2018

Mileage

99,000 mi

TL* THE CONTACT OWNS A 2002 TOYOTA TACOMA. THE CONTACT TOOK THE VEHICLE TO TOYOTA OF PORTLAND (55 NE BROADWAY ST, PORTLAND, OR 97232, (503) 284-1105) TO BE REPAIRED PER NHTSA CAMPAIGN NUMBER: 12V542000 (TIRES). THE CONTACT WAS INFORMED THAT THE RECALL REPAIR COULD NOT BE PERFORMED DUE TO EXCESSIVE RUST ON THE VEHICLE'S FRAME. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 212,000.

NHTSA ID

11151511

Incident

Sep 1, 2017

Mileage

212,000 mi

I RECEIVED A RECALL FOR A SPARE TIRE HOLDER. I TOOK THE VEHICLE TO LE MIEUX TOYOTA-GREEN BAY FOR REPAIR AND THEY TOLD ME THAT THEY COULD NOT DO IT BECAUSE THE FRAME WAS TOO RUSTED OUT AND REMOVING THE OLD SPARE TIRE CARRIER WOULD MAKE THE PROBLEM WORSE. LE MIEUX SAID THAT THERE WAS AN EARLIER RECALL THAT ADDRESSED THE FRAME ISSUE. I DID NOT RECEIVE THAT RECALL. I CALLED DIRECTLY TO TOYOTA USA HOME OFFICE AND THEY REFUSE TO FIX THE RUSTING FRAME ISSUE. I BELIEVE THAT THIS HAPPENED MAYBE 2-3 YEARS AGO. I WAS NOT GIVEN A REASON FOR REJECTING MY REQUEST FOR THE REPAIR., AND I KNOW THAT LE MIEUX TOYOTA HAS FIXED OTHER TOYOTA VEHICLES WITH THE SAME ISSUES. I BELIEVE THAT THEY WOULD NOT FIX MY VEHICLE BECAUSE I AM A 2ND OWNER. I HAVE HAD SERVICE ISSUES WITH THIS DEALER ON 3 OTHER SEPARATE OCCASIONS, AND I HAVE REFUSED TO DO BUSINESS WITH THEM. WITH THIS RECALL ISSUE I HOPED FOR A POSITIVE SOLUTION, BUT THAT HAS NOT HAPPENED.

NHTSA ID

11145273

Incident

Aug 1, 2016

Mileage

160,000 mi