2003 Toyota Tundra Body & structure Problems

NHTSA Campaign 09V444000 for 2000-2003 Toyota Tundra to address severe corrosion on the rear frame cross-member section or rear brake lining proportion valve. Vehicle was apparently treated with CRC in 2010, but vehicle continued to rust severely in the specified recall zone, even after Toyota Safety Recall 90M had been completed on the vehicle. The CRC applied to the rear frame cross-member of the frame as specified did not inhibit further corrosion of the rear frame cross member, if anything it accelerated the corrosion. Thousands of 2000-2003 Toyota Tundras titled in the specified severe cold weather states still remain in use, and pose a threat to the overall safety of drivers. The Toyota 90M Safety recall did not adequately inhibit the corrosion of the rear frame section, rendering the vehicle unserviceable & unable to align, and leaving gas tanks, rear suspension, rear drive train, and spare tire parts susceptible to falling off of the vehicle and causing an accident- posing a risk of severe injury/death to road users. I am asking that the NHTSA please look into reissuing the NHTSA Campaign 09V444000 to have all 2000-2003 Toyota Tundras still registered for road use in severe cold weather states be inspected by a certified Toyota dealership for repairs, frame replacement, or vehicle buybacks to prevent unnecessary accidents due to a manufacturer defect that was never rectified properly.

NHTSA ID

11734951

Incident

Apr 10, 2026

NHTSA Campaign 09V444000 for 2000-2003 Toyota Tundra to address severe corrosion on the rear frame cross-member section or rear brake lining proportion valve. Vehicle was apparently treated with CRC in 2010, but vehicle continued to rust severely in the specified recall zone, even after Toyota Safety Recall 90M had been completed on the vehicle. The CRC applied to the rear frame cross-member of the frame as specified did not inhibit further corrosion of the rear frame cross member, if anything it accelerated the corrosion. Thousands of 2000-2003 Toyota Tundras titled in the specified severe cold weather states still remain in use, and pose a threat to the overall safety of drivers. The Toyota 90M Safety recall did not adequately inhibit the corrosion of the rear frame section, rendering the vehicle unserviceable & unable to align, and leaving gas tanks, rear suspension, rear drive train, and spare tire parts susceptible to falling off of the vehicle and causing an accident- posing a risk of severe injury/death to road users. I am asking that the NHTSA please look into reissuing the NHTSA Campaign 09V444000 to have all 2000-2003 Toyota Tundras still registered for road use in severe cold weather states be inspected by a certified Toyota dealership for repairs, frame replacement, or vehicle buybacks to prevent unnecessary accidents due to a manufacturer defect that was never rectified properly.

NHTSA ID

11730991

Incident

Apr 10, 2026

The frame was undercoated incorrectly and is actively falling apart. Super unsafe to drive. Very clearly was not undercoated correctly as there is areas in the frame that have no signs of undercoating. This is putting the driver of the vehicle at risk as well as the other drivers on the road. This is a huge recall that was issued for this model of year truck. Very common. The vehicle has not been inspected by the dealer as they refused to inspect it or even acknowledge the issue. There is no warning lamps on but it is visibly unsafe to drive

NHTSA ID

11721706

Incident

Mar 1, 2026

The frame was not professionally undercoated and is actively falling apart. Super unsafe to drive.

NHTSA ID

11721589

Incident

Mar 1, 2026

The frame is bad on driver and passenger side between the cab and bed. Auto body tech states there is no good metal to make the necessary repairs (welding new metal) to at this time. Inspection garage states it is a solid truck but will not pass inspection due to the frame’s condition. The vehicle has 106k miles on it with one surface area of rust. The vehicle has been well maintained and is mechanically in good condition. Toyota should have replaced the frames because they knew there was an issue. Can NHTSA help with a resolution?

NHTSA ID

11718123

Incident

Dec 15, 2025

There was a recall for the frame rusting out prematurely. Toyota had the recall until 2012. I did not own the truck then and it did not get fixed. Now I have a rusted out frame. Toyota is claiming they are not able to fix the frame due to it being 14 years later. They would however be able to keep the recall open if it is a safety recall. I don't know how a rusted out frame wouldn't be anything other than safety. The truck has less than 80,000 miles. What automobile should have a rusted out frame with less than 100,000 miles?!

NHTSA ID

11715509

Incident

Jan 26, 2026

Frame rusted out causing gas tank to fall off truck while driving. Was sparking while trying to pull of to a safe spot on highway, tank was hanging on by the fuel line. Leaf spring also broke on truck do to rust. Cars were avoiding my truck on highway as sparks were coming from the gas tank shield scrapping the highway. Frame should have been replaced along with gas lines, and leaf springs during the recall in 2012 range. Toyota of York decided to just undercoat spray frame, prior to me purchasing truck from them. They never notified me (the consumer) of the recall that was current on truck.

NHTSA ID

11662394

Incident

May 15, 2025

The 2003 Toyota Tundra is known for severe frame rot due to improper rust protection, which led to a major safety recall. The excessive corrosion can cause rust holes to form in the frame, compromising the vehicle’s structural integrity. This can lead to frame cracking or even complete failure, making the truck extremely dangerous to drive. A weakened frame affects the vehicle’s ability to absorb impact in a crash, reduces stability, and can lead to suspension or steering failure. In extreme cases, parts like the fuel tank or spare tire can detach, increasing the risk of a serious accident.

NHTSA ID

11648060

Incident

Mar 13, 2025

The contact owns a 2003 Toyota Tundra. The contact stated while in the process of selling the vehicle, the potential buyer inspected the subframe and informed the contact that the frame was severely rusted inside and outside. The vehicle was taken to an independent mechanic, where it was inspected. The mechanic confirmed the failure and informed the contact that the six bolts holding the bed securely were severely rusted. The contact was provided an estimate for a partial external repair of the subframe. The vehicle was not repaired. The contact stated that the dealer had previously sprayed a corrosion protective compound on the vehicle under NHTSA Campaign Number: 09V444000 (Structure); however, the failure progressively worsened. The dealer and the manufacturer were notified of the failure. The vehicle was not repaired. The failure mileage was approximately 119,000.

NHTSA ID

11646668

Incident

Feb 28, 2025

Mileage

119,000 mi

The contact owns a 2003 Toyota Tundra. The contact stated while working underneath the vehicle, he became aware that the junction point on the frame rail of the front driver’s side was rusted. The vehicle was taken to the dealer where the rust was confirmed and pictures and documentation that the frame needed to be replaced were submitted to Toyota Chicago regional however, the subframe replacement was denied by the dealer. The manufacturer was contacted who informed the contact to find another 2003 Toyota Tundra owner where they had remedied the frame rust failure free of charge. The contact stated that the other vehicle owner informed him that Toyota offered to replace the frame or buy back the vehicle. The contact stated he provided the information to Toyota with the other owner's information and VIN, however, the contact stated that Toyota had not offered to replace the frame or buy back the vehicle. The contact stated that the vehicle was serviced in 2013 under NHTSA Campaign Number: 09V444000 (Structure) at Toyota West (1500 Auto Mall Dr, Columbus, OH 43228) however, the rust failure occurred. The contact stated that the remedy was insufficient. The contact stated that a case was opened. The approximate failure mileage was 200,000.

NHTSA ID

11588676

Incident

Dec 23, 2019

Mileage

200,000 mi

In October 2024, my truck's frame exhibited significant rust, a defect that aligns precisely with a previous recall on this model. The rust has spread to critical parts, making the vehicle unsafe to drive. This directly threatens the safety of my son, who relies on this truck for transportation. The rust compromises the frame's integrity, risking structural failure and potential loss of vehicle control. This defect was not previously flagged by warning lamps or messages and was only recently discovered through visual inspection. This issue has been documented in the past and is consistent with a recall initiated a year ago. This recall specifically cited frame rust as a critical defect, and my vehicle is one of those affected models. Given the safety concerns, the severity of frame rust, and the recall history, the frame needs immediate replacement. This action is crucial to ensure my son's safety and prevent potentially life-threatening incidents on the road.

NHTSA ID

11586230

Incident

Apr 30, 2024

On 4/19/2024 I arrived for an appointment at Corwin Toyota of Bellvue, Nebraska for inspection of my vehicles known recall of the frame due to excessive rust and potential failure due to a faulty manufacturing process. My vehicle is a 2003 Toyota Tundra SR5, Access Cab. Upon arrival, the service representative, and later corroborated by his manager, refused to inspect my vehicle stating "work had already been done on my frame". That is not true. I am the original owner of said vehicle and had it inspected in approximately 2010 after being informed of the recall, likely at a dealership in Denver Colorado where i was residing at the time. At that time was informed vehicle frame did not have excessive rust and NO work was done. The vehicle was purchased in Colorado Springs from Corwin Toyota (same dealership franchise company?), in 2003. Since then, the vehicle has lived in Nebraska and Iowa for most of its existence where salt is used on roads extensively in the winter. I was informed by the service representative at the dealership they will not look at it as they show it has already had repairs done to the frame as I stated. This is false. No work has been done on my vehicles frame at any point and is now experiencing significant frame rust. At some point, maybe at inspection in 2010, maybe later, that some work had been done making the frame ineligible for future inspection or repair or replacement. I am sure Toyota and its agents, Toyota dealerships, are highly motivated to exclude as many vehicles associated with this frame recall as possible. I am certain I am not the only one experiencing this fraud on the consumer. Please investigate whom allegedly did work on my frame, when, and what specifically. I expect the ability to have my frame legitimately inspected and actual repairs or replacement of effected part(s) as resolution. I will be contacting the manufacturer but expect the same run around without your direct involvement. Thank you in advance.

NHTSA ID

11584231

Incident

Apr 19, 2024

The contact owns a 2003 Toyota Tundra. The contact stated that an unknown recall for structure corrosion was completed on the vehicle in February 2012 at a local dealer. The contact stated on June 2022, he noticed that the subframe was corroded. The vehicle was taken to an independent mechanic, where it was diagnosed that the subframe needed to be replaced. The local dealer was made aware of the failure. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was approximately 145,000.

NHTSA ID

11513996

Incident

Feb 1, 2012

Mileage

145,000 mi

I just bought the Toyota I was told that he had brought this Toyota to a dealership and it was sent to har some sealant sprayed on frame to prevent anymore rust. The whole frame and the spare tire holder thing is total rusting out and the motor mounts are even rusting out is there a recall on his veichle if not there should be

NHTSA ID

11510235

Incident

Feb 26, 2023

Frame is rusted and unsafe to be driven. I loved this truck but now what good is it?

NHTSA ID

11497313

Incident

Dec 12, 2022

The frame on this truck is completely rusted. There are several holes and cracks in the frame. You can pull chunks of the rusted frame off with your fingers. It is unsafe to drive and is a hazard to other drivers There are many photos online of this model of truck that have broken in half when the frame has failed. There are stories of people who are driving this vehicle and it breaks in half while on the highway causing injury. I took it to our local mechanic in June who said this truck is unsafe. I contacted the Iowa Attorney General's office and made a complaint. They put me in contact with Toyota's corporate office who referred me to their Brand Experience Center. They said it had to be evaluated by a Toyota dealer. I took it to the original dealer who sold this vehicle - Wilson Toyota in Ames Iowa- on September 27, 2022. Their service center says the frame needs replaced. They said they would not pay for any repairs. They said this truck had two safety recalls to replace the frame but they said they expired in 2012. I spoke to Toyota's Brand Experience Center again on the 27th and was told that my truck did not have any rust on it when it was taken in for the recall. Nothing was done to this vehicle when it was taken in for the recall repairs. There are many posts on Toyota forums that describe the same thing happening to other owners of this truck. - They are unaware of this condition of their truck frames until they bring it in to a reputable mechanic. The attached photos of this truck show the upper body is in good shape. But the frame is falling apart.

NHTSA ID

11487052

Incident

Jun 23, 2022

I have a 2003 Toyota Tacoma 2 wheel drive The frame is rotted With only a 140000 miles on itAnd the manufacturer won't help me anymore so I don't know what to do with this vehicle now.

NHTSA ID

11468755

Incident

Jun 11, 2022

The contact owns a 2003 Toyota Tundra. The contact stated while the vehicle was being emissions tested, he was informed that the sway bars and the rear cross members were corroded. The VIN was associated with NHTSA Campaign Number: 09V444000 (Structure). The contact took the vehicle to the local dealer and was informed that the location of the corrosion was not covered under the recall. The vehicle was not repaired. The contact took the vehicle to several independent mechanics who declined to service the vehicle due to the damage of the corrosion. The vehicle was not repaired. The manufacturer had been informed of the failure. The failure mileage was approximately 153,000.

NHTSA ID

11439678

Incident

Oct 1, 2021

Mileage

153,000 mi

Frame is rotten. Recently purchased truck from a private party. Did not notice frame rust at time of purchase. It is bad. Can fit more than a marble through the hole in picture. Read up on it online. Common problem. Upon going underneath truck all frame is decaying. It appears it may have previously been sealed. Which may have cracked away and trapped moisture in just making problems worse. On top of that one thread I read stated guy took his truck to dealer and they told him by law they could not let him leave due to rust issue. Mine is an 2003 Toyota Tundra sr5 access cab 2wd terminator edition. Please help. I was also able to look up on Toyota website under owners and found a shop stated not safe to drive or even lift in November of 2020. And since then truck has only had about 700 miles put on. 120 miles was from guy driving it to me to sell to me. I’m now worried if I drive this in it’s current state that at any time it could break and cause an accident.

NHTSA ID

11437103

Incident

Oct 17, 2021

The contact owns a 2003 Toyota Tundra. The contact stated while having the vehicle repaired under an unknown recall, he was informed that the sub frame needed to be replaced. The manufacturer was informed of the failure but offered no assistance. The failure mileage was approximately 118,485.

NHTSA ID

11425104

Incident

Jul 12, 2021

Mileage

118,485 mi

2003 Toyota Tundra. Consumer writes in regards to NHTSA safety recall related to rusted frames.

NHTSA ID

11423188

Incident

Jul 2, 2021

UNSAFE TO DRIVE SO MUCH CORROSION ON FRAME

NHTSA ID

11414683

Incident

Mar 2, 2021

Mileage

40 mi

MY TUNDRA 2003 SR5 ACCESSCAB 4X4 TRD. IT HAS RUSTED SO BAD THE LAST 5 YRS. IT WILL NO LONGER PASS HAWAII SAFETY INSPECTION. I HAVE HAD THE TRUCK SINCE ABOUT 2007. IT HAS BEEN A GREAT RUNNING TRUCK. ENGINE AND TRANSMISSION ARE IN GOOD SHAPE. NEW BRAKES. BUT THE RUST HAS RUINED THE FRAME, TAILGATE AND BACK OF BED! HAVE NOT DRIVEN FOR A YEAR!

NHTSA ID

11404397

Incident

Jan 1, 2016

FROM 2001-2003 IS A FRAME RECALL ON THESE TUNDRA'S DUE TO MASSIVE RUST ISSUE. I WENT INTO MY LOCAL TOYOTA DEALERSHIP HERE IN NORFOLK, VA, AND THEY GAVE ME THE RUN AROUND SAYING I "MISSED THE WINDOW" FOR THIS ISSUE. THEN I CALLED CORPORTATE AND THEY GAVE ME A DIFFERENT REASON, SAYING THEY "APPLIED" ANTI-RUST SPRAY" IN 2016. WHICH IS NOT A THING. CLEARLY IT DID NOT WORK BECAUSE THERE ARE MASSIVE HOLES IN MY FRAME. I WOULD LIKE THEM TO OWN UP AND DO MY RECALL WHEN SO MANY OTHER PEOPLE I KNOW HAVE THE EXACT SAME TRUCK AND GOT THEIRS DONE. I AM ACTIVE DUTY AS WELL, AND IT FRUSTRATES ME THAT THEY WOULD TREAT A VETERAN LIKE THIS. I BROUGHT UP MY SPARE TIRE LATCH BEING VERY RUSTED UNDERNEATH, WHICH THERE IS ALSO A RE-CALL FOR. THEY SAID THEY COULD NOT DO ANYTHING FOR ME. 3 WEEKS LATER MY SPARE TIRE FLEW OFF FROM MY TRUCK, THANK GOODNESS NO ONE WAS INJURED.

NHTSA ID

11403602

Incident

Aug 14, 2020

Mileage

195,000 mi

RECALL ID U7BS-ZTW. TOOK IN FOR AIRBAG RECALL. INSPECTION OF FRAME. FRAME NEEDS TO BE REPLACED AND DEALERSHIP WOULD NOT LET ME HAVE MY TRUCK BACK.THEY GAVE ME A INFERIOR LOANER.. TOOK TRUCK IN FIRST WEEK OF S JANUARY.AS OF 3-5-21 THEY HAVE NO REPAIR SCHEDULE EITHER!. TRUCK IS AT TOYOTA OF MUNCIE IN. ALEC BAILY IS MY SERVICE MANAGER. ABAILY@TOYOTAOFMUNCIE. WORK ORDER NUMBER NC736011 AND NCOO1101. I HAVE BEEN IN CONTACT WITH TOYOTA CUSTOMER EXPERIENCE SINCE FEBRUARY. SEVERE RUN AROUND. INCIDENT #S 210125000031, 210217000381,210304000232. NATIONAL REF#S 210250103,2103042076. IF IT CANNOT BE REPAIRED I WOULD LIKE TO KNOW

NHTSA ID

11399249

Incident

Jan 5, 2021