2009 Toyota Tacoma

The contact owns a 2009 Toyota Tacoma. The contact stated that the frame on the driver’s and passenger’s side was severely rusted. The dealer was contacted about the failure and about the warranty enhancement program ZH6, which was associated with the failure. The manufacturer had extended the warranty coverage for frame corrosion on certain 2005–2010 model year Toyota Tacoma vehicles. The dealer informed the contact that the program had expired. The manufacturer was made aware of the failure. The manufacturer informed the contact that the warranty program had expired. The failure mileage was approximately 217,000.

NHTSA ID

11747159

Incident

Jun 28, 2026

Mileage

217,000 mi

Unknown.no accident ,Steering is tight. Started noticing it May 12 2026.

NHTSA ID

11743521

Incident

May 12, 2026

Real bumper assembly rotted off the frame was dragging behind the truck I'm at 60mph luckily nobody was behind me pulled over and removed it all both frame rails was rusted in half Hanging On by a little piece every place I called will not fix it want me to buy a whole frame truck has 220 miles on it with no rear bumper

NHTSA ID

11739530

Incident

Sep 6, 2024

Odometer Fraud. The contact purchased a 2009 Toyota Tacoma. The contact discovered a mileage discrepancy after the purchase. The vehicle was a private sale. At the time of purchase, the vehicle mileage was 127,619. It was later discovered through Carfax in August 2025 that the mileage on the Title was 297,651.

NHTSA ID

11695505

Incident

Oct 23, 2025

Mileage

297,651 mi

The contact owns a 2009 Toyota Tacoma. The contact stated that after maintenance service on the vehicle, it was discovered that the front subframe of the vehicle was severely corroded. The vehicle was taken to an independent mechanic, where it was inspected, and determined that the entire subframe had failed and needed to be replaced. The vehicle was not repaired. The vehicle was then taken to the dealer, where the same diagnostic result was provide,d and the contact was informed that the entire subframe needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure. The approximate failure mileage was 85,000.

NHTSA ID

11695033

Incident

Oct 22, 2025

Mileage

85,000 mi

The contact owns a 2009 Toyota Tacoma. The contact stated that upon further inspection, the contact became aware that the chassis was rusted. The local dealer was contacted; however, the contact was informed that an unknown Toyota recall for warranty coverage had expired. The manufacturer was made aware of the failure. The failure mileage was approximately 110,000.

NHTSA ID

11694959

Incident

Jan 15, 2025

Mileage

110,000 mi

THE FRAME HAS RUSTED AND HOLES ARE UNSAFE. I AM WORRIED ABOUT DRIVING MY VEHICLE. THE SAFETY OF ME AND OTHER DRIVERS ON THE ROAD I AM TRAVELING ARE AT RISK. I WENT TO LIBERTY TOYOTA IN BURLINGTON, NJ AND THEY REFUSED TO REPAIR. THE RUST IS UNUSUAL AND THERE HAVE BEEN OTHER YEARS AFFECTED AND FRAMES REPLACED. MY WIFE PURCHASED THIS TRUCK FROM LIBERTY TOYOTA

NHTSA ID

11693714

Incident

Sep 13, 2024

Vehicle: 2009 Toyota Tacoma VIN: [XXX] Mileage: 128,400 Owner: Jacob Grove, Anderson, SC Summary of Issue: The frame of this 2009 Toyota Tacoma has developed severe rust perforation that makes the vehicle unsafe to drive. My independent mechanic has refused to work on it due to safety concerns, and Toyota of Greenville (SC) has confirmed that the frame is extensively corroded and requires replacement. Background: Toyota previously issued a Customer Support Program (CSP) for frame corrosion affecting 2005–2009 Tacomas in northern states, including Ohio, where this truck was purchased and operated. In June 2018, the vehicle was inspected at Don Wood Toyota in Athens, OH (91,600 miles). The dealership recorded “no perforation” and did not apply the protective coating or replace the frame. The truck has been minimally driven since (an average of 6,000 miles per year). In May 2024, at 128,400 miles, a mechanic and dealership confirmed the frame has multiple areas of severe perforation, including around brake lines and exhaust mounts. Concern: It is unreasonable that a vehicle frame could go from “no perforation” to “severe perforation” in only 36,000 miles and six years of light use. This indicates either: The 2018 inspection under Toyota’s CSP was inadequate, or The frame was already compromised but not properly addressed at the time. Safety Risk: The vehicle cannot be safely lifted, worked on, or driven in its current condition. The rapid deterioration presents a risk of frame failure while driving, endangering occupants and others on the road. Request: I am submitting this complaint so that NHTSA is aware of ongoing frame corrosion failures in 2005–2009 Toyota Tacomas, even in cases where Toyota previously inspected and declined to repair during the CSP period. This case demonstrates that the problem may not have been properly identified or corrected during program inspections, leaving unsafe vehicles on the road. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11682040

Incident

May 1, 2024

Some 2005 – 2026 Toyota vehicles that have undergone water intrusion may exhibit a condition in which a musty odor is present. Follow the procedures in this bulletin to remediate the odor and address this condition. The purpose of this Service Bulletin is to provide general guidelines and procedures for odor remediation. This Service Bulletin provides a guide on how to prepare and treat the interior of the vehicle for odor remediation. Refer to the applicable model and model year Repair Manual and the EPA (Environmental Protection Agency) website for the most up-to-date safety and precautionary guidelines.

Acid rain results from rainwater or other airborne moisture that become acidic due to industrial chemical impurities in the atmosphere. If these acidic compounds settle on an exposed vehicle, especially the horizontal areas such as the hood, roof, and decklid, significant damage to the painted surfaces can occur. Acid rain damage can typically be identified on vehicles by the presence of stains on the paint surface that resemble hard water spots. Unlike water spots however, acid rain damage cannot be removed by regular washing procedures. Also, because acid rain can etch and soften the paint, normal buffing or polishing repair procedures should not be attempted. This can cause further damage and result in visible depressions in the paint surface. The following are the three major categories of acid rain damage: •Minor damage: requires only buffing to repair. •Moderate damage: usually requires neutralizing, color sanding, and buffing. •Severe damage: extending beyond 1/2 mil of clearcoat on a pearl, metallic, or solid color, requires neutralization, sanding, and repainting. In cases where acid rain damage is minor, neutralization and buffing with a liquid-type paint finessing product may provide an adequate repair. Only specially formulated products outlined in this bulletin should be used for that purpose. Unfortunately, other than minor damage, there is no simple method of determining the actual extent (depth) of acid penetration other than color sanding a representative affected area until there is no visible etching or depressions, followed by measuring the amount of paint removed with either a magnetic or digital-type film thickness gauge. The procedures in this bulletin are intended for use by qualified body/paint technicians and should not be attempted by inexperienced personnel. It is the dealer’s responsibility to protect and maintain the quality of the vehicle’s paint finish after receipt at the dealership prior to the first sale. Perform frequent vehicle washing, as often as daily, during high heat and humidity periods to minimize the potential for paint damage due to acid rain exposure. This is especially important in geographical areas known for high frequency and concentration of acid rain and industrial fallout.

The condition known as acid rain is caused by airborne chemicals or particles in the atmosphere, which mix with rainwater, nighttime dew, or high humidity to form acidic compounds. If these contaminants settle and remain on a painted vehicle surface, especially the horizonal areas of the hood, roof, and decklid, significant damage can occur. This damage is the result of actual etching of the paint and appears as pitting or water spots. As acid rain droplets on the vehicle surface evaporate, the concentration strength of the acid increases, causing deeper and more rapid damage. This evaporation and corrosive action also occur more rapidly on dark colored cars as direct sun heat increases. It is the dealer’s responsibility to protect and maintain the quality of the vehicle’s paint finish after receipt at the dealership prior to the first sale. In areas known for high frequency and/or concentration of acid rain, frequent vehicle washing during high heat or humidity periods will minimize the potential for paint damage caused by acid rain. It is further recommended that either reverse osmosis or deionized water be used to prevent water spotting.

To prevent brake rotor rust from forming during transportation and storage, wheel film will be used instead of a cardboard type of anti-rust cover. The purpose of the wheel film is to shield the disc brake rotor from weather elements and initial rust before the vehicle is delivered to the customer. Consequently, the film should remain on the wheel for as long as possible.

Toyota vehicles are currently protected with RapgardTM protective film designed to protect the horizontal painted surfaces. This material protects from acid rain, environmental fallout, and rail contamination. Follow the Removal Procedure in this bulletin to remove the RapgardTM protective film within 90 days from initial application.

Vehicles may occasionally be subjected to contamination by airborne iron particles shed from railroad tracks, train wheels, exposure to heavy machinery facilities, grinding, welding, etc. This type of contamination can be identified by the presence of small, red or brown particles on the paint surface. These particles are often difficult to see on dark color paints but can be easily felt when brushing a hand across horizontal body surfaces such as the hood, roof, or deck lid. Follow the Repair Procedure in this bulletin to clean vehicles that may have been subjected to contamination by airborne iron particles such as rail dust during rail transportation or extended storage near industrial areas.