2004 Toyota Tacoma Fuel system Problems

2011- check engine light was illuminated. Toyota dealership attempted repairs 11 times but could not find a cause. They replaced 7 different sensors, replaced gas cap, charcoal filter.. still could not get light to go off. refused to continue servicing same issue with no fault. Since 2011, I have had to run diagnostics on a regular basis to ensure there are no other mechanical issues. 2022- gas tank fell off of truck while driving. The straps snapped off due to rust and tank fell to the ground. This issue could have caused GREAT bodily injury or DEATH. 2023-lost brakes while driving. TOTAL brake failure. local mechanic stated it was a proportioning valve failure. The housing for it was rusted through and cannot be removed safely. After multiple days of research, a replacement could not be located. Even contacting Toyota, part is unavailable so vehicle CANNOT be fixed. Total brake failure could have led to GREAT bodily injury or DEATH. ONGOING-- vehicle frame is extremely rusted. bumper has fallen off, spare tire fell off, brush guard rusted and fell off. The frame under cab near bed of truck is rusted through. gas tank straps rusted through and tank fell off. You can literally push fingers/hand through the flaking metal. ALL previous recalls were completed including undercoating but the rust has gotten so bad the vehicle is not safe to drive.

NHTSA ID

11527190

Incident

May 30, 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

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

FUEL TANK STRAP FAILED TANK DROPPED PUSHING SHIELD INTO DRIVESHAFT CAUSING METAL TO METAL GRINDING. THIS HAPPENED AFTER FILLING TANK AND DRIVING.

NHTSA ID

11300445

Incident

Jan 17, 2020

Mileage

14,900 mi

TL* THE CONTACT OWNS A 2004 TOYOTA TACOMA. THE CONTACT NOTICED AN ABNORMAL ODOR COMING FROM THE FUEL TANK. THE CONTACT DROVE HOME AND PARKED THE VEHICLE. THE FOLLOWING MORNING, THE CONTACT NOTICED FUEL LEAKING FROM THE FUEL TANK ONTO THE DRIVEWAY WITHOUT WARNING. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT THE FUEL TANK NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED, BUT THE FAILURE RECURRED. THE VEHICLE WAS TOWED TO ASHLAND HONDA TOYOTA (2301 LAKE SHORE DR E, ASHLAND, WI 54806, (715) 682-5252). THE DEALER ORDERED THE FUEL TANK AND SENT IT THE INDEPENDENT MECHANIC. THE VEHICLE WAS TAKEN BACK TO THE INDEPENDENT MECHANIC WHO DIAGNOSED THAT THE FUEL TANK NEEDED TO BE REPLACED FOR THE SECOND TIME AFTER ONE YEAR. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 130,000.

NHTSA ID

11246087

Incident

Sep 20, 2017

Mileage

130,000 mi

WHILE DRIVING I HEARD AN UNUSUAL NOISE COMING FROM UNDERNEATH THE VEHICLE. UPON SELF INSPECTION I DISCOVERED THE FUEL TANK STRAP HAD BROKE. I NOTICED ALSO THAT THE FUEL TANK SHIELD LOOKED LIKE SWISS CHEESE FROM CORROSION. I HAD A TIE DOWN STRAP THAT I WAS ABLE TO USE TO STRAP THE SHIELD AND TANK UP WITH. I AM IN THE PROCESS OF LOOKING TO REPAIR IT. I FEEL SINCE IT IS A SAFETY ISSUE TOYOTA SHOULD FIX IT FREE OF CHARGE. A FUEL TANK STRAP SHOULD NEVER FAIL LIKE THIS.

NHTSA ID

11063152

Incident

Jan 15, 2018

Mileage

135,000 mi

GAS TANK, TANK SHEID BRACKET HOLDING TANK UP ALMOST COMPLETLY RUSTED OFF WITH HARDLY HOLDING GAS TANK ON! MAJOR ISSUE!

NHTSA ID

10953929

Incident

Feb 9, 2017

Mileage

117,500 mi

MY PICKUP WAS JUST REFRAMED UNDER TOYOTA RECALL AT TOYOTA OF BEDFORD,OHIO. BUT,, THEY OMITTED THE SAFETY SHIELD UNDER THE FUEL TANK.. AKA ..GRAVEL SHIELD.. FIRST SAYING IT NEVER HAD ONE, THEN IT WAS MISSING, THEN IT DIDN'T COME IN THE KIT, I FILED A CASE WITH TOYOTA USA, CORPORATION # 1701033889 AS PER ALL SAFETY ITEMS WERE TO BE MAINTAINED OR REPLACED !! BUT I WAS DENIED BY TOYOTA CORP. SO I WILL HAVE TO PICK UP MY TRUCK UNDER PROTEST AS TOYOTA OF BEDFORD IS THREATENING ME WITH CALLING THE LOANER CAR IN AS STOLEN IF I DON'T TODAY ! SAID SHIELD WAS "RUSTY" BUT MOST WAS ON THE TRUCK WHEN IT WENT IN THERE, AND IM ON SOCIAL SECURITY (SMALL CHECK) WHICH OUR GREAT OBAMA CARE TAKES ALMOST FIVE EIGHTS OF & I REALLY CANT AFFORD THE $ 640.- THEY ARE ASKING JUST FOR THE PART ! I REALLY DON'T FEEL SAFE IN THE TRUCK WITHOUT THE SHIELD , SO IT WILL PROBABLY SIT TILL BETTER WEATHER & I CAN MAKE A SHIELD FOR IT..AND IT WILL BE STRONGER & LAST MUCH LONGER THAN THE PIECE OF "RUSTY TIN, " THAT THEY SAY FELL AWAY. SO AGAIN , IM PICKING IT UP UNDER PROTEST & WILL WRITE THAT ON THE BILLING STATEMENT TODAY 1/52017... [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

NHTSA ID

10939914

Incident

Jan 5, 2017

Mileage

176,000 mi

DRIVING AT 35 MPH, HEAR A DRAGGING NOISE AND PULL TO THE SIDE OF THE ROAD. I LOOKED UNDER THE CAR A SAW THAT THE METAL STRAPS HOLDING THE GAS TANK TO THE CAR HAD RUSTED THRU, ALLOWING THE TANK TO DROP DOWN TO ABOUT 3 INCHES ABOVE THE ROADWAY, CAUSING THE TANK TO DRAG THE GROUND

NHTSA ID

10766452

Incident

Sep 21, 2015

Mileage

151,141 mi

THE OWNER FOUND A RECALL ON 2004 TOYOTA TACOMAS ON THE INTERNET. THIS RECALL SPECIFIED THAT THERE WAS A MANUFACTURING DEFECT IN THE FORMULATION OF THE UNDERCOATING. THIS MANUFACTURING DEFECT RESULTED IN THE RUSTING OF THE SUSPENSION, AND TIRE PLATE. UPON INSPECTION OF THE VEHICLE BY A TOYOTA DEALER, IT WAS FOUND THAT THE A-FRAME IS RUSTED THROUGH, THE LEAF SPRINGS ARE FAILING AND ARE BOWED IN THE OPPOSITE DIRECTION, GAS TANK MOUNTS ARE RUSTED AND THE UNDER BODY OF THE GAS TANK HOUSING IS RUSTING THROUGH. TOYOTA DEEMED THE VEHICLE UNSAFE BUT REFUSED TO DO ANYTHING BECAUSE THE RECALL HAD EXPIRED. THE OWNER NEVER RECEIVED A NOTICE BY MAIL DURING THE RECALL PERIOD. IF THE OWNER WOULD HAVE RECEIVED THE RECALL NOTICE HE WOULD HAVE BROUGHT THE VEHICLE IN FOR INSPECTION AND REPAIR. THIS VEHICLE HAS LOW MILEAGE AND IF IT WERE NOT FOR THESE MANUFACTURING DEFECTS, COULD BE DRIVEN FOR ANOTHER 10 YEARS. CONTACT WITH ANY COMMON ROAD HAZARD SUCH AS A BUMP OR POT HOLE COULD CAUSE THE BOW SPRINGS TO FAIL, AND THERE IS A POSSIBILITY OF GAS TANK RUPTURE, EXPLOSION AND DEATH.

NHTSA ID

10748763

Incident

Jul 30, 2015

Mileage

85,000 mi

FROM A DEAD STOP TO ANY SPEED, IT FELT LIKE I NO ACCERATION. I WOULD HAVE TO FEATHER THE GAS PEDAL TO GET UP TO SPEED. I'VE REPLACED FUEL FILTER, 02 SENDER ( FRONT), MAF SENDER ,FUEL PRESSURE REGULATOR ,CLEANED ALL GROUNDS, HAD FUEL PUMP TESTED , HAD HEAD GASKET CHECKED ,CHANGED SPARK PLUGS AND WIRE'S, CLEANED THROTTLE BODY AND PRESSURE CLEANED FUEL SYSTEM. EVERY TIME I CHANGE A PART OR DO ANY CLEANING , THE TRUCK WILL RUN FINE, FOR AWHILE , BUT THE PROBLEM RETURNS. I NOW HAVE 150K ON TRUCK ,AND I WANT TO GET 150 K MORE. I FELL THIS IS A EXTREMELY HAZARDS SITUATION. ALL I'M LOOKING FOR IS A ANSWER TO WHAT'S WRONG!!!! TOYOTA IS AWARE OF WHAT'S WRONG ,BUT THE DEALERS ONLY TO KEEP REPLACING PARTS ($) . THE TOYOTA FORUM S ON WEB HAVE 1000S OF ANSWER S, BUT, NOTHING DEFINITE. PLEASE HELP!!!!

NHTSA ID

10723721

Incident

Jun 1, 2014

Mileage

120,000 mi

WHILE ON A SHORT SHOPPING TRIP I SUDDENLY HEARD A LOUD RATTLING/BUZZING NOISE COMING FROM UNDERNEATH THE VEHICLE. I DROVE TO MY LOCAL CAR REPAIR WHERE THEY NOTICED WHILE I WAS PULLING INTO THEIR DRIVEWAY THAT THE TRUCK FUEL TANK WAS BOUNCING DANGEROUSLY AND WAS ON THE VERGE OF FALLING OFF. BOTH THE FUEL TANK HOLDER ( A LARGE STEEL PLATE ) AND THE FUEL TANK STRAP HAD RUSTED THRU AND WERE NO LONGER SUPPORTING THE TANK. I SHUDDER TO THINK WHAT MIGHT HAVE HAPPENED IF THE TANK HAD FALLEN. ADDING INSULT TO INJURY, THIS VEHICLE WAS IN FOR A RECALL ON 2/13/12 FOR REPAIR OF RUST ON THE FRAME AT MILES 52449 ). ON 6/18/13 IT WAS IN FOR ANOTHER RECALL TO FIX RUST ON THE REAR TIRE CARRIER WHICH WAS REPLACED ( AT MILES 61103 ). AT NEITHER OF THESE RECALLS WAS I TOLD OF EXCESS RUST ON THE TANK HOLDER AND YET WITH ADDITIONAL MILEAGE OF 8612 MILES BOTH THE FUEL TANK STRAP AND HOLDER FAILED. THIS MISHAP COULD HAVE CAUSED A DISASTER. *TR

NHTSA ID

10701148

Incident

Mar 17, 2015

Mileage

69,715 mi

WHILE DRIVING ALONG I WOULD SOMETIMES HEAR AN UNUSUAL SOUND, A SLIGHT RINGING SOUND. WHEN I RETURNED HOME AND INSPECTED MY TRUCK I SAW THAT ONE OF THE METAL STRAPS THAT HOLDS THE GAS TANK IN PLACE HAD RUSTED APART, AND THE BRACKET WOULD RUB AGAINST THE DRIVE SHAFT, CREATING THE SOUND. THIS IS ONE OF THE TACOMA'S THAT WAS RE-FRAMED AS PART OF A RECALL. IT APPEARS THE SAME DEFECTIVE METAL USED IN THE FRAME THAT WAS REPLACED WAS ALSO USED IN OTHER COMPONENTS. THE GAS TANK COULD HAVE FALLEN, DROPPED ON TO THE ROAD, OR SIMPLY EXPLODED, NO DOUBT KILLING MYSELF AND MY WIFE. I HAD THE GAS TANK STRAPS REPLACED AT A LOCAL GARAGE. I ALSO HAVE PICTURES OF THE BROKEN STRAP IF YOU WOULD LIKE TO SEE THEM. *TR

NHTSA ID

10629696

Incident

Aug 2, 2013

Mileage

45,000 mi

TL* THE CONTACT OWNS A 2004 TOYOTA TACOMA. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 5 MPH, SHE NOTICED SOMETHING HAD BECOME DETACHED FROM UNDER THE VEHICLE. THE CONTACT INSPECTED THE VEHICLE AND NOTICED THAT THE FUEL TANK PROTECTOR WAS CORRODED AND HAD CAUSED THE FUEL TANK TO BECOME DETACHED. THE VEHICLE WAS NOT TAKEN TO A DEALER FOR DIAGNOSTIC TESTING. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE AND CURRENT MILEAGE WAS 61,400...UPDATED 10/30/13 *BF THE CONSUMER STATED THE DEALER FOUND THE VEHICLE HAD A PREFORATION. THE FRAME AND THE STRAPS FOR THE FUEL TANK WERE REPLACED. FREE OF CHARGE. *JS

NHTSA ID

10546210

Incident

Sep 20, 2013

Mileage

61,400 mi

ON SEVERAL OCCASIONS MY TRUCK HAS COMPLETELY LOST POWER. A FEW TIMES IT HAPPENED WHILE PULLING INTO TRAFFIC RESULTING IN ME ALMOST BEING HUNG OUT IN A BUSY INTERSECTION. WHEN I PUSH THE GAS PEDAL, IT STARTS TO MOVE FORWARD, THEN SUDDENLY LOSES POWER. I BELIEVE THE PROBLEM IS SOMEWHERE IN THE THROTTLE BODY. I ALSO GET SOME HESITATION WHEN LIGHTLY HITTING THE ACCELERATOR AT HIGHWAY SPEEDS. *JB

NHTSA ID

10541912

Incident

Nov 1, 2012

Mileage

100,000 mi

TL* THE CONTACT OWNS A 2004 TOYOTA TACOMA. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 10 MPH, SHE NOTICED SOMETHING HAD BECOME DETACHED FROM UNDER THE VEHICLE. THE CONTACT INSPECTED THE VEHICLE AND NOTICED THAT THE FUEL TANK PROTECTOR WAS CORRODED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC FOR DIAGNOSIS. THE MECHANIC STATED THAT THE FUEL TANK PROTECTOR WOULD HAVE TO BE REPLACED. THE VEHICLE WAS REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 98,000. *TR

NHTSA ID

10509585

Incident

Nov 5, 2012

Mileage

98,000 mi

GAS TANK SHIELD CORRODING WHEN NOTIFIED BY TOYOTA ABOUT CORROSION PROBLEMS TO THE FRAME OF THE TRUCK, I INSPECTED THE UNDER NEATH OF THE TRUCK MYSELF AND ALSO NOTICED THE GAS TANK SHIELD HAD CORRODED AWAY. WHEN I WENT TO THE DEALER TO HAVE THE FRAME CHECKED, I TOLD THEM ABOUT THE PROBLEM WITH THE GAS TANK SHIELD AND THEY TOLD ME THAT WAS NOT PART OF THE RECALL.NOW A YEAR LATER, I JUST RECEIVED ANOTHER RECALL FOR A DIFFERENT PROBLEM," EXCESSIVE CORROSION OF THE SPARE TIRE CARRIER PLATE". IF THE FRAMES AND SPARE TIRE CARRIER PLATES CORRODE DUE TO HIGH ROAD SALT USE IN COLD CLIMATE STATES, WHY ARE THE GAS TANK SHIELDS CORRODING ? THIS IS A VERY DANGEROUS SAFETY ISSUE, THAT NEEDS TO BE ADDRESSED. *TR

NHTSA ID

10491715

Incident

Mar 12, 2012

Mileage

122,000 mi

I BROUGHT MY TRUCK TO A TOYOTA DEALER TO LOCATE AN EMISSIONS SYSTEM LEAK. TWO OTHER MECHANICS HAD SPENT HOURS TRYING TO DIAGNOSE THE PROBLEM AND WERE UNABLE TO FIND THE LEAK. THE TOYOTA TECH FOUND THE LEAK IN LESS THAN 20 MINUTES. THAT WOULD LEAD ME TO BELIEVE HE HAD DEALT WITH THIS PROBLEM BEFORE. THE LEAK TURNED OUT TO BE CORROSION IN THE FUEL TANK, WHERE THE FILLER NECK MEETS THE TANK. I WOULD NOT EXPECT A RUSTED GAS TANK IN AN 8 YEAR OLD TRUCK. THE REPAIR ESTIMATE WAS OVER $1400, THE PART ALONE WAS $750. THIS IS A TRUCK THAT HAD ALREADY BEEN RECALLED FOR A RUSTED FRAME (WHICH TOYOTA REPLACED AT NO COST TO ME) AND IS SHOWING CORROSION IN THE REAR BUMPER AND TAILGATE. I SUSPECT TOYOTA SAVED MONEY BY BUILDING THE TRUCK WITH INFERIOR MATERIALS. BUT MORE IMPORTANTLY, A LEAKING FUEL TANK IS A HUGE SAFETY ISSUE, NOT COMMON IN A VEHICLE THIS RECENT. *TR

NHTSA ID

10488733

Incident

Sep 5, 2012

Mileage

138,664 mi

TL* THE CONTACT OWNS A 2004 TOYOTA TACOMA SR5. THE CONTACT STATED THAT FUEL FUMES WERE EMITTED INTO THE VEHICLE. THE VEHICLE WAS TAKEN TO THE DEALER, WHO DIAGNOSED THAT THERE WAS A HOLE IN THE FUEL TANK. AS A RESULT, THE FUEL TANK AND SENDING UNIT NEEDED TO BE REPLACED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE, BUT DID NOT OFFER ANY ASSISTANCE. THE VEHICLE WAS REPAIRED. THE FAILURE AND CURRENT MILEAGES WERE 111,000.

NHTSA ID

10455669

Incident

Apr 12, 2012

Mileage

111,000 mi

AT A STOP, VEHICLE DOES NOT ACCELERATE AFTER DEPRESSING THE GAS PEDAL. 2 OCCASIONS NEARLY CAUSED AN ACCIDENT. ALSO, AT CRUISING SPEEDS (60-70 MPH) VEHICLE WILL DECELERATE WITHOUT ANY CHANGE IN PRESSURE TO THE GAS PEDAL. *NM

NHTSA ID

10153523

Incident

Mar 8, 2006

Mileage

25,000 mi

2004 TOYOTA TACOMA 4X4 WITH 3.4L ENGINE AND MANUAL TRANS. HAVING THROTTLE BODY ISSUES. THE ACCELERATOR POSITION SENSOR IS FAILING CAUSING THE TRUCK TO STALL FOR A SECOND AND THEN PICK BACK UP. TRUCK DOES NOT THROW A CHECK ENGINE CODE WHEN THIS OCCURS, SO DEALER HAS INFORMED ME ON DIFFERENT OCCASIONS THAT NOTHING IS WRONG. I WAS ALMOST RAN OVER THE OTHER DAY TRYING TO PULL OUT INTO TRAFFIC WHEN THE THROTTLE BODY FAILED. THIS IS A SAFETY CONCERN AND TOYOTA NEEDS TO ADDRESS IT IMMEDIATELY!!!!!!!! WHAT'S IT GOING TO TAKE, SOMEONE GETTING SERIOUSLY INJURED OR A HEALTHY LOW SUIT FOR TOYOTA TO TAKE ACTION? *JB

NHTSA ID

10146664

Incident

Dec 30, 2005

Mileage

15,000 mi

SMALL ROCK WAS HIT ON A DIRT ROAD. IT PUNCTURED THE GAS TAKE. HAD VEHICLE TOWED TO DEALER. GAS TANK WAS REPLACED. *NM

NHTSA ID

10143894

Incident

Nov 21, 2005

Mileage

18,600 mi

DT:THE CONTACT STATED THE FUEL LINE CAUGHT ON FIRE O. WHILE STOPPING AT A RED-LIGHT HE NOTICED THERE WERE FLAMES COMING FROM BETWEEN THE CAB AND BED OF THE PICKUP TRUCK. THE FIRE WAS EXTINGUISHED, AND THE VEHICLE WAS TOWED TO THE DEALERSHIP. THE DEALERSHIP HAD THE VEHICLE FOR NINE WEEKS. THE VEHICLE HAS BEEN REPAIRED, AND IS READY TO BE PICKED UP. THE CAUSE OF THE FIRE WAS FROM THE FUEL LINE AND THE SEAL OF THE FUEL TANK.*AK

NHTSA ID

10142429

Incident

Sep 3, 2005

Mileage

17,576 mi

AFTER RUNNING THE VEHICLE AND SHUTTING IT OFF FOR ABOUT 2 HOURS THE VEHICLE DID NOT WANT TO START, THERE WAS ONLY ABOUT 2,000 MILES ON THE TRUCK. THE STARTER IS CRANKING THE ENGINE, BUT THE ENGINE IS NOT STARTING UP. I TOOK IT TO THE TOYOTA SERVICE DEPARTMENT, AND THEY SAID NOTHING WAS WRONG WITH THE VEHICLE. THE SAME THING HAPPEND SEVERL TIMES AFTER I HAD TAKEN IT TO TOYOTA. THE ONLY WAY TO START THE VEHICLE WOULD BE TO CRANK IT UP FOR ABOUT 5 MINUTES, THEN THE VEHICLE WOULD RUN ROUGH FOR ABOUT A MINUTE. I TOOK IT TO THE TOYOTA SERVICE DEPARTMENT AGAIN AND THIS TIME THEY WORKED ON IT. THEY SAID THEY HAD TO CHANGE THE THROTTLE POSITION SENSOR, THE ENGINE WIRING HARNESS, AND THE FUEL INJECTORS. NO OLD PARTS WERE AVAILABLE. PROBLEM HAS STILL NOT BEEN CORRECTED. VEHICLE NOW HAS ABOUT 6,000 MILES AND EVERY 3-4 DAYS IT STILL DOESN'T WANT TO START UP. *AK

NHTSA ID

10106156

Incident

Nov 15, 2004

Mileage

2,000 mi