2004 Toyota Tacoma Body & structure Problems

Immediately after the manufacturer recall requiring full frame replacement (completed November 2017 by the same dealership referenced below), the vehicle developed abnormal handling not present before the repair, including improper tracking and rear end instability. No warning lights/diagnostic messages were present. These issues were reported to the servicing dealership within weeks and repeatedly over the following years. Despite multiple short initial inspections and two extended service periods—totaling approximately fourteen months in the dealership’s possession—the dealership repeatedly reported no defect found and continued to advise that the vehicle was safe to operate. Due to ongoing safety concerns, an independent inspection was recently obtained. It confirmed measurable rear axle offset and a thrust angle deviation outside acceptable tolerances. The defect is visually apparent: the rear wheels are not symmetrically aligned, and the vehicle exhibits a noticeable “crab walking” effect when viewed from behind. The root cause remains undetermined and would require further diagnostic work and significant disassembly. All documentation and inspection findings are available upon request. Safety risk: The vehicle does not track correctly and shows instability, especially in low traction conditions such as rain or snow, increasing the risk of loss of control. The manufacturer has been formally notified through repeated outreach, including ongoing contact with the Brand Engagement Center since December 2025 and multiple certified letters to Toyota North America Legal/Consumer Affairs between January and March 2026. The only response received was a generic statement from the Brand Engagement Center indicating that the vehicle is out of warranty and an offer to return it to the same dealership that performed the frame replacement and failed to identify the defect. No other response, investigation, or resolution has been provided by Toyota North America.

NHTSA ID

11726891

Incident

Nov 20, 2017

The frame broke

NHTSA ID

11688089

Incident

Sep 1, 2025

The vehicle has an open recall (NHTSA Recall #12V542) for the spare tire carrier lift plate. I brought the vehicle to a Toyota dealership to have the recall addressed, but the dealership refused to perform the repair, stating that the frame is too rusted to proceed safely. They recommended a full frame replacement due to severe rust damage, which includes holes and significant structural weakening. Toyota has refused to provide a replacement frame under any existing recall or warranty program. This means the recall cannot be completed, and the vehicle remains unsafe to drive. Additionally, I cannot locate a replacement frame for this vehicle through Toyota or the aftermarket, leaving no practical solution to address the safety risks. The refusal to honor the recall and the lack of available replacement parts put me and others at significant risk. The problem has been confirmed by the Toyota dealership during inspection, and the rust damage makes the vehicle structurally unsound. The unresolved recall, combined with the excessive frame rust, has created a double safety hazard that needs urgent resolution

NHTSA ID

11631075

Incident

Dec 13, 2024

Vehicle was taken to dealer with frame rust, crack and holes. Toyota refused to fix , repair or offer parts to repair.

NHTSA ID

11568678

Incident

Jan 29, 2024

The contact owns a 2004 Toyota Tacoma. The contact had taken the vehicle to Kolosso Toyota (3000 W Wisconsin Ave, Appleton, WI 54914) to have his exhaust replaced. While there, he was informed that the entire sub frame was corroded with several cracks and holes had formed around both front leaf springs. The mechanic informed him that the vehicle was unsafe to drive due to the failure. Prior to the failure, the contact took the vehicle to another local dealer where the vehicle was inspected under NHTSA Campaign Number: 05V225000 (Suspension). The contact was informed that a special coating was sprayed onto the sub frame to prevent corrosion; however, the recall remedy failed to prevent the corrosion. The manufacturer was contacted but provided no assistance. The vehicle was not repaired. The failure mileage was 51,641.

NHTSA ID

11513413

Incident

Jun 19, 2018

Mileage

51,641 mi

Bought the vehicle in May 2022 from a dealer. By November of 2022 it was discovered that the frame was totally rusted. The dealer won't help so I paid $10,000 for a truck that lasted 6 months. I then found out this was a common problem that Toyota knew about so I called them for assistance. They would not help. I have been renting a vehicle at a cost of $800 a month because I don't have the money to buy another vehicle.

NHTSA ID

11511452

Incident

Nov 1, 2022

What component or system failed or malfunctioned, and is it available for inspection upon request? The whole frame, the chassis, it is rusty specially in the front How was your safety or the safety of others put at risk? when the rusty becomes worse, it will compromise the entire vehicle estructure, even the suspension and wheel parts. Has the problem been reproduced or confirmed by a dealer or independent service center? Yes, I can see Toyota run a recall process until 2019 Has the vehicle or component been inspected by the manufacturer, police, insurance representatives or others? No, just regular shop service, on which they reported high damage for the suspension and frame parts. Were there any warning lamps, messages or other symptoms of the problem prior to the failure, and when did they first appear?. It is making bad noises and suspension parts are difficult to replace

NHTSA ID

11507649

Incident

Jan 10, 2023

The contact owns a 2004 Toyota Tacoma. The contact stated while driving 20 MPH and making a right turn, the vehicle lost motive power and stalled. There was no warning light illuminated. The contact was able to veer to the side of the road. The vehicle failed to restart after several attempts. The vehicle was towed to the dealer, where it was diagnosed that the Electronic Fuel Injection (EFI) main fuse had blown due to a short circuit. The dealer replaced the Electronic Fuel Injection (EFI) main fuse; however, the failure persisted. Additionally, the dealer diagnosed that the subframe was severely corroded, including transmission components and fuel system components. The manufacturer was notified of the failure and informed the contact that they could not assist as unknown recalls had expired. The vehicle was not repaired. The failure mileage was approximately 150,000.

NHTSA ID

11501675

Incident

Nov 13, 2022

Mileage

150,000 mi

Frame is badly rusted as a result truck is not driveable..

NHTSA ID

11496303

Incident

Dec 1, 2022

The contact owns a 2004 Toyota Tacoma. The contact stated that while looking underneath the vehicle, he noticed that the subframe was rusted. The local dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was not notified of the failure. The approximate failure mileage was 176,000.

NHTSA ID

11491583

Incident

Oct 30, 2022

Mileage

176,000 mi

The contact owns a 2004 Toyota Tacoma. The contact stated upon taking the vehicle to an independent mechanic for a tire replacement, he was informed that the passenger’s side subframe was severely corroded. The contact notified several unknown dealers of the failure. The dealers informed the contact that there was no recall associated with the VIN. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was approximately 233,000.

NHTSA ID

11485662

Incident

Sep 20, 2022

Mileage

233,000 mi

Excessive Corrison through out the frame.Was informed bu certified mechanic really it is unsafe to drive. What can I do I still owe money on this vehicle.

NHTSA ID

11485341

Incident

Aug 23, 2022

Financed a 2004 Toyota Tacoma and found that frame of truck is rusted out and not sure what to do, can't afford new frame and still owe a little over 9 grand for it....please advise what to do next. Thank u

NHTSA ID

11483273

Incident

Aug 1, 2022

The frame has rusted and broke behind the cab

NHTSA ID

11471457

Incident

Jun 20, 2022

The contact owns a 2004 Toyota Tacoma. The contact stated that the underside of the vehicle started to flake and fall off in pieces. The vehicle was taken to a local dealer where it was diagnosed with needing the frame replaced however, the vehicle was not repaired. The manufacturer was not informed of the failure. The failure mileage was approximately 165,000.

NHTSA ID

11449257

Incident

Dec 1, 2021

Mileage

165,000 mi

FRAME RUST

NHTSA ID

11449041

Incident

Jan 24, 2022

This vehicles frame has rusted and broken. I feel lucky to have made it home just as the frame cracked wide open on one side making the truck un-drivable. Had this happened on the freeway or somewhere out in a rural setting I may have been killed, caused a problem for other drivers or been stranded away from any help. I have sent a photo of the damage to a frame shop but an independent inspection is not, in my opinion, needed since the rusted, broken member is clearly visible to any lay person. There were no warning lights or anything associated with this problem. What I did feel was some serious shaking and bumping as I moved down the road toward my house.

NHTSA ID

11441647

Incident

Nov 15, 2021

2004 TOYOTA TACOMA. CONSTITUENT WRITES REGARDING A CRACKED FRAME ON VEHICLE. *LD THE CONSUMER STATED THE MANUFACTURER WAS NOTIFIED BUT, DENIED ANY ASSISTANCE. THE CONSUMER STATED THE MANUFACTURER ADVISED THERE WAS A RECALL IN 2010 THAT EXPIRED IN 2019. THE PREVIOUS OWNER DID NOT HAVE THE REPAIR COMPLETED. *JS

NHTSA ID

11405552

Incident

Jan 21, 2021

FRAME ROT ON THE MID CHASSIS UP TO THE FRONT CHASSIS WHERE THE FRAME BEGINS TO CURVE INWARD TOWARDS THE ENGINE. FRAME ROT IS ON LEFT AND RIGHT SIDE OF THE VEHICLES INNER FRAME. FAILED STATE INSPECTION.

NHTSA ID

11398904

Incident

Mar 3, 2021

CALLED TOYOTA 2 YEARS AGO ABOUT RUST ON MY TRUCKS FRAME NEAR THE REAR LEAF SPRING MOUNTING AREA. WAS BLOWN OFF BY TOYOTA CUSTOMER CARE. IN DECEMBER WAS DRIVING AND THE FRAME RAILS LITERALLY SNAPPED AN BOWED, THE ONLY THING THAT SAVED MY LIFE WHILE DRIVING 70MPH, ON THE INTERSTATE 70 BETWEEN HAGERSTOWN MD AND HANCOCK MD, HOME FROM WORK WAS THE BED CONTACTING THE CAB OF THE TRUCK AND MIRACULOUSLY HOLDING HOLDING IT UP AND ALLOWING ME TO GET IT SAFELY OFF THE ROAD AND CALL MY MECHANIC. THE SHEET METAL OF THE TRUCK IS RUST FREE AND IN GOOD CONDITION. THE FRAME IS A TOTAL LOSS. THE TRUCK WAS AT TOYOTA IN 2010 AND 2011 FOR FRAME INSPECTIONS. THIS IS A KNOWN ISSUE WITH THESE TRUCKS AND NOW IM TOLD THAT TOYOTA WONT DO ANYTHING ABOUT IT. IF THEY WOULD HAVE FIXED IT OR ADDRESSED MY CONCERNS IN 2018 OR EVEN 2019 I WOULDNT HAVE NEARLY CRASHED MY TRUCK. THE IDEA OF A SAFETY CAMPAIGN IS THAT THEY KNOW THERE IS AN ISSUE, THEIR WAS A CLASS ACTION SUIT, THEY HAVE FRAMES AVAILABLE AND THEY NEED TO REPLACE MY FRAME ON MY TRUCK AND MAKE IT SAFE AGAIN. IT IS THE ONLY TRUCK I HAVE I USED IT TO TAKE CARE OF MY DOGS AND MY THE ROADS TO MY HOME ARE VERY STEEP AND A 2WD OR FRONT WHEEL DRIVE WILL NOT MAKE IT IN SNOWY OR RAINY WEATHER. TOYOTA'S CASE # IS 2102242008, PHONE NUMBER TO CALL IS 1800-331-4331.

NHTSA ID

11397815

Incident

Dec 17, 2020

Mileage

185,000 mi

RE: DEFECTIVE FRAME ON 2004 TOYOTA TACOMA EXTEND CAB DEAR SIR OR MADAM: I AM REACHING OUT TO YOU FOR ASSISTANCE REGARDING THE DEFECTIVE FRAME ON MY 2004 TOYOTA TACOMA EXTENDED CAB. I PURCHASED THIS VEHICLE USED IN 2012 FROM A PRIVATE OWNER. I DID NOT KNOW AT THE TIME, NOR DID THE PREVIOUS OWNER ADVISE ME THAT HE RECEIVED A MANUFACTURER'S RECALL ON THE TRUCK FROM TOYOTA IN 2010 REGARDING A CRACKED FRAME BECAUSE THE VEHICLE WAS NOT TREATED DURING MANUFACTURING TO PROHIBIT RUST CORROSION. PLEASE SEE ATTACHED LETTER.

NHTSA ID

11390414

Incident

Jan 19, 2021

2004 TACOMA FRAME SO ROTTED THAT UPON HITTING A LARGE HOLE WOULD FINISH OFF THE RUSTED FRAME. THIS TYPE OF RUST AND EROSION IS NOT FROM NORMAL WEAR.. THIS IS DUE TO THE MANUFACTURING OF THE VEHICLE AND THEY WILL NOT REPLACE. THEY SAY THEY ARE AWARE OF IT.. BUT TIME LAPSED TO GET IT FIXED?? SO WHAT NOW I AM OUT $15K ON A 16 YEAR OLD TRUCK. SINCE WHEN DID RECALLS HAVE AN EXPERATION DATE??

NHTSA ID

11376720

Incident

Nov 27, 2020

PURCHASED 2004 TACOMA IN 2016. DEALERSHIP OF PURCHASE SAID VEHICLE WAS NOT AFFECTED BY FRAME RECALL AND DID NOT INFORM ME THAT IT WAS UNDER WARRANTY FOR FRAME RELATED ISSUES. SINCE PURCHASING VEHICLE I'VE ENCOUNTERED COUNTLESS FRAME RELATED ISSUES AND HAVE PUT THOUSANDS INTO FRAME RELATED REPAIRS. I CONTACTED TOYOTA IN 2018 ON SEVERAL OCCASIONS TO ASK ABOUT FRAME WARRANTY. TOYOTA SAID VEHICLE WAS NOT COVERED. DID NOT LOOK UP VIN OR ANY OTHER INFORMATION RELATED TO VEHICLE. I CONTACTED TOYOTA AGAIN THIS YEAR TO SEE IF THERE'S ANYTHING THAT CAN BE DONE AS FRAME ISSUES WERE BECOMING SIGNIFICANT AND BEYOND MY FINANCIAL MEANS TO KEEP FIXING. TOYOTA NOTIFIED ME AT THIS TIME THAT THE VEHICLE HAD IN FACT BEEN UNDER WARRANTY BUT THAT NOW THE WARRANTY HAD EXPIRED 6 MONTHS PRIOR (WHICH WAS WITHIN THE TIMEFRAME THAT I HAD INITIALLY CONTACTED TOYOTA). TOYOTA TOLD ME THAT FRAME HAD BEEN UNDERCOATED WITH CORROSION RESISTANCE TREATMENT IN 2010 AND WARRANTY WAS GOOD FOR 10 YEARS (UNTIL 2020). BECAUSE DEALERSHIP OF PURCHASE FAILED TO COMPLY WITH A WARRANTY LETTER AND TOYOTA ALSO FAILED TO NOTIFY ME AS I WAS NOT THE ORIGINAL OWNER, I WAS NOT AWARE THAT I COULD HAVE HAD THE FRAME FIXED. WHICH I WOULD HAVE IF I HAD KNOWN. NOW BECAUSE OF NO FAULT OF MY OWN, THE WARRANTY WINDOW HAS CLOSED AND TOYOTA IS NOT WILLING TO RECTIFY THE SITUATION. I STILL OWE OVER $3K ON A VEHICLE I PAID OVER $11K FOR AND HAVE PUT $4K-$8K INTO FOR REPAIRS. FRAME IS ROTTING FASTER THAN I CAN FIX IT AND IS NOW UNSAFE TO DRIVE AND INELIGIBLE FOR TRADE-IN OR SALE BECAUSE THE VEHICLE IS ESSENTIALLY WORTHLESS AT THIS POINT. FRAME BOLTS ARE NOW ROTTED, TAILPIPE AND EXHAUST FELL OFF JUST THIS MORNING DUE TO CORROSION, SUSPENSION IS CORRODED, BRACKETS ARE ROTTING OFF FRAME, FLAKES OF CORRODED METAL ARE IN PILES BENEATH VEHICLE- AND THESE ARE JUST THE MOST RECENT ISSUES.

NHTSA ID

11365078

Incident

Mar 3, 2017

Mileage

119,000 mi

TL* THE CONTACT OWNS A 2004 TOYOTA TACOMA. THE CONTACT STATED THAT APPROXIMATELY 12 YEARS THE VEHICLE WAS TREATED WITH A RUST INHIBITOR HOWEVER, THE SUBFRAME WAS SEVERELY RUSTED. ADDITIONALLY, THERE WERE SEVERAL RUST HOLES TO THE SUBFRAME. THE CONTACT CONTACTED TOYOTA OF VINELAND (650 N DELSEA DR, VINELAND, NJ 08360, (856) 559-7690) WHO STATED THAT THEY WERE UNABLE TO PROVIDE THE REPAIR UNDER A RECALL. THE DEALER ALSO STATED THAT THE SUBFRAME NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE ISSUE AND OPENED A CASE. THE APPROXIMATE FAILURE MILEAGE WAS 120,165. *LN THE CONSUMER SUBMITTED PHOTOS. *TR

NHTSA ID

11355539

Incident

Sep 10, 2020

Mileage

120,165 mi

MY 2004 TOYOTA TACOMA HAS FRAME DAMAGE UNDERNEATH (PICTURE ENCLOSED) I LEARNED OF A 15 YEAR MANUFACTURER EXTENDED WARRANTY ON THE FRAME OF MY TRUCK WITHIN THE LAST FEW MONTHS. I PUT IN A COMPLAINT TO TOYOTA (I LOST CLAIM NUMBER) AND WAS TOLD THE WARRANTY HAD EXPIRED IN MAY OF 2019 AND WAS OUT OF LUCK, HE ALSO SAID THAT 15 YEAR WARRANTY EXTENSION WERE MAILED OUT IN THE PAST BUT ,TROUBLE IS MY WIFE AND I DO NOT RECALL SEEING THIS INFORMATION DO TO THIS I WAS UNABLE TO GET MY FRAME FIXED UNDER THE WARRANTY AND I CANNOT AFFORD OUT OF POCKET FEE TO FIX MYSELF. WHAT ISSUE I DO HAVE IS I HAD MY VEHICLE AT A TOYOTA DEALERSHIP BEING WORKED ON FOR A "SAFETY RECALL " JULY OF 2018 AND I WAS WONDERING AT LEAST AS A CUSTOMER COURTESY WHY I WASN'T MADE AWARE OF THIS FRAME RECALL WHILE UNDER REPAIR FOR THE SAFETY RECALL, I WOULD HAVE GOT THE WORK DONE HAD I KNOWN AND AS STATED EARLIER KNOWN BY RECEIVING INFORMATION IN THE MAIL ABOUT THIS. THE TOYOTA REP SAID SINCE IT EXPIRED I WAS OUT OF LUCK AND THAT IS WHY I'M REACHING OUT TO YOU ABOUT THIS MATTER. *TR

NHTSA ID

11326589

Incident

Mar 10, 2020

Mileage

141,000 mi