2003 Toyota Tundra Fuel system Problems

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 contact owns a 2003 Toyota Tundra. The contact stated while driving at 30 MPH, the brake pedal was depressed several times but failed to respond and went all the way to the floorboard. The contact's son intentionally hit a curb and downshifted in order to stop the vehicle. The vehicle was towed to an independent mechanic where it was diagnosed that the subframe was severely corroded and an unknown axle was leaking and causing the brake failure. Additionally, the independent mechanic diagnosed that the gas tank was detaching from the vehicle due to the frame corrosion. The vehicle was not repaired. The manufacturer was notified of the failure but provided no assistance. The failure mileage was approximately 146,000.

NHTSA ID

11478825

Incident

Aug 8, 2022

Mileage

146,000 mi

TL* THE CONTACT OWNS A 2003 TOYOTA TUNDRA. WHILE DRIVING 65 MPH, THE CONTACT HEARD AN ABNORMAL DRAGGING NOISE COMING FROM THE VEHICLE. UPON EXITING THE VEHICLE, THE CONTACT NOTICED THAT THE FUEL TANK WAS RUSTED AND DETACHED. ALSO, THE CHECK ENGINE INDICATOR ILLUMINATED. THE CONTACT CALLED DON MOORE TOYOTA (4216 FREDERICA ST, OWENSBORO, KY 42301, (270) 926-2500) AND WAS INFORMED TO HAVE THE VEHICLE TOWED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS CONTACTED AND DID NOT ASSIST. THE FAILURE MILEAGE WAS 129,000. *BF *JB

NHTSA ID

11204005

Incident

Apr 1, 2019

Mileage

129,000 mi

TL* THE CONTACT OWNS A 2003 TOYOTA TUNDRA. WHILE DRIVING VARIOUS LOW SPEEDS AND APPROACHING A STOP, THE FUEL TANK DETACHED FROM THE VEHICLE AND FELL ONTO THE GROUND. THE CONTACT TEMPORARILY RE-ATTACHED THE FUEL TANK TO THE VEHICLE AND WAS ABLE TO DRIVE HOME. ROMANO TOYOTA (6400 BASILE ROWE, EAST SYRACUSE, NEW YORK 13057, (315) 445-1070) WAS MADE AWARE OF THE FAILURE AND REQUESTED THAT A DIAGNOSTIC TEST BE PERFORMED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE CONTACT REFERENCED NHTSA CAMPAIGN NUMBER: 09V444000 (STRUCTURE). THE FAILURE MILEAGE WAS APPROXIMATELY 155,000.

NHTSA ID

11153073

Incident

Nov 16, 2018

Mileage

155,000 mi

AS I WAS TRAVELING AT A SLOW SPEED WHEN I BECAME AWARE OF A LOUD GRINDING NOISE WHICH HAD SUDDENLY BEGAN AS I TURNED ONTO A SIDE STREET. I STOPPED VEHICLE IMMEDIATELY AND GOT OUT TO INVESTIGATE WHAT WAS CAUSING THE NOISE. I DISCOVERED THAT MY FUEL TANK WAS DRAGGING BENEATH THE TRUCK. THE METAL STRAPS THAT HELD TANK TO FRAME HAD RUSTED THRU CAUSING TANK TO FALL TO ROAD SURFACE. ALL THE CONNECTIONS TO FUEL TANK WERE RIPPED FROM TANK. TOYOTA IS WORRIED ABOUT THE SPARE TIRE FALLING DOWN DO TO RUSTED FRAME MEMBERS BUT I FEEL THEY SHOULD BE MORE WORRIED ABOUT THEIR FUEL TANKS FALLING OFF. IF I HAD BEEN TRAVELING AT HIGHWAY SPEEDS I HATE TO THINK OF WHAT CONSEQUENCES MIGHT HAVE BEEN. *JS

NHTSA ID

10608682

Incident

Jun 28, 2014

Mileage

110,500 mi

I WAS DRIVING DOWN THE ROAD WHEN THE 'CHECK ENGINE' LIGHT CAME ON. I TOOK IT TO THE DEALER TO SEE WHAT THE ISSUE WAS AND THEY STATED IT WAS A LEAK IN THE GAS CAP AND THAT I DIDN'T HAVE CAP TIGHT ENOUGH. ON THE WAY HOME FROM THE DEALER THE 'CHECK ENGINE' LIGHT CAME BACK ON, SO I TOOK IT BACK TO THE DEALER. THEY STATED THAT THE FUEL FILLER NECK NEEDED TO BE REPLACED AND IT'S NOT COVERED UNDER WARRANTY. *TR

NHTSA ID

10535151

Incident

Jul 10, 2013

Mileage

74,500 mi

TOOK 2003 TOYOTA TUNDRA IN FOR FRAME RUST CORROSION PROGRAM 09V-444000. WAS TOLD FRAME AND OTHER COMPONENTS HAD EXTENSIVE RUST AND MULTIPLE 10MM HOLES BY LEAD SERVICE TECHNICIAN AT LOCAL TOYOTA DEALERSHIP. SERVICE MANAGER EXPLAINED THAT MY 2003 TOYOTA TUNDRA FRAME WAS EXTENSIVELY RUSTED AND UNSAFE TO BE ON THE ROAD AND THEY WANTED TO TAKE MY TRUCK IMMEDIATELY AND PROVIDE A RENTAL CAR DUE TO SAFETY CONCERNS. ASKED FOR A PLAN OF ACTION OF THE SCOPE OF WORK TO BE PERFORMED (CORROSION COMPOUND VERSES FRAME REPLACEMENT) BEFORE GIVING POSSESSION OF VEHICLE. PHOTOS OF 2003 TOYOTA TUNDRA FRAME, REAR CROSS MEMBERS, SPARE TIRE CARRIER, REAR BRAKE LINES & FUEL TANK MOUNTING SYSTEM WERE TAKEN AND SENT TO LEAD SERVICE TECH THREE STATES AWAY IN TEXAS. WAS INFORMED EXTENSIVE FRAME RUST EXISTS ON ALL COMPONENTS (FRAME, REAR CROSS MEMBERS, SPARE TIRE CARRIER, REAR BRAKE LINES & FUEL TANK MOUNTING SYSTEM) BUT IT IS NOT COVERED BECAUSE VEHICLE IS NO LONGER REGISTERED IN WISCONSIN. PURCHASED THIS 2003 TOYOTA CERTIFIED VEHICLE IN WISCONSIN IN APRIL OF 2010 AND NO INFORMATION WAS GIVEN TO ME AT REGARDING THE NHTSA INVESTIGATION OR ANY RUST INSPECTIONS THAT WERE PERFORMED. TOYOTA CORPORATION REFUSES TO REPAIR, REPLACE OR ADD CORROSION RESISTANT COMPOUND TO ANY SEVERELY AFFECTED RUSTED COMPONENTS. SIGNIFICANT RUST ISSUES EXIST ON THIS VEHICLE AND STILL TOYOTA CORPORATION REFUSES TO PROVIDE ANY DOCUMENTATION OF THEIR INSPECTIONS. TOYOTA CORPORATION WILL NOT PUT IN WRITING THAT THE FRAME, REAR CROSS MEMBERS, SPARE TIRE CARRIER, REAR BRAKE LINES & FUEL TANK MOUNTING SYSTEM IS SAFE OR ROAD WORTHY. DEADLINE FOR ALL RUST REPAIRS IS DECEMBER 31, 2012. TOYOTA CORPORATION IS STALLING CONSUMERS TO KEEP FROM DOING ANY REPAIRS AND LEAVING UNSAFE RUSTED 2003 TOYOTA TUNDRA'S ON THE HIGHWAYS. PLEASE INITIATE A NEW NHTSA INVESTIGATION REGARDING THIS MATTER FOR THE SAFETY OF CONSUMERS. *TR

NHTSA ID

10483681

Incident

Nov 2, 2012

Mileage

55,000 mi

MY TOYOTA HAD A FRAME RECALL FOR RUSTING WHICH THEY FIXED. NOW I'M BEING TOLD MY GAS TANK IS RUSTING AND NEEDS TO BE REPLACED. TOYOTA WILL FIX IT FOR 1500. 00 DOLLARS I BELIEVE THIS IS A SAFETY PROBLEM AND IS A TOYOTA PROBLEM. *TR

NHTSA ID

10471426

Incident

Jun 29, 2012

Mileage

79,232 mi

CHECK ENGINE LIGHT ON. CODE RELATED TO EVAPORATION/FUEL SYSTEM. CHECKED THE FUEL CAP, APPEARS OK, RESET LIGHT AND RETURNED ON. WILL REPLACE FUEL CAP. POTENTIALLY FUEL FILLER PIPE AS MENTIONED FREQUENTLY ON HERE. *TR

NHTSA ID

10461400

Incident

May 18, 2011

Mileage

83,000 mi

I RECEIVED THE SSC 90M - TUNDRA VEHICLES SEVERE CORROSION OF THE REAR CROSS MEMBER PHASE 2 - CRC APPLICATION. MY TRUCK HAS A TONNEAU COVER AND A BED RUG INSTALLED. WHEN I CALLED THE DEALERSHIP TO SCHEDULE AN APPOINTMENT THEY INFORMED ME THAT THE BED OF THE TRUCK WOULD HAVE TO BE REMOVED TO COMPLETE THE REPAIRS. I TOLD THEM THAT I DID NOT HAVE THE MEANS TO REMOVE THE TONNEAU COVER AND THE BED RUG. THEY SAID THAT THEY COULD NOT PERFORM THE REPAIR WITHOUT THESE ITEMS REMOVED AND THAT THEY WOULD NOT REMOVE THEM FOR ME. I THEN CONTACTED TOYOTA CUSTOMER EXPERIENCE CENTER AT 800-331-4331, EXTENSION [XXX] AND DISCUSSED THE SITUATION WITH [XXX]. SHE CLAIMED THAT THE RECALL LETTER STATES THAT THE TRUCK MUST BE PRESENTED IN "FACTORY CONDITION" (I GUESS THAT MEANS NO BED RUG OR TONNEAU COVER). I REREAD THE LETTER AND THAT IS NOT STATED ANYWHERE IN THE LETTER. I CALLED HER BACK AND SHE WAS UNABLE TO ASSIST ME NOR WOULD SHE ELEVATE MY ISSUE TO THE MANAGEMENT LEVEL. THIS RECALL WORK MUST BE DONE, AND AGAIN, I HAVE NO MEANS TO REMOVE THESE ITEMS. I'M SURE THAT I'M NOT THE ONLY TUNDRA OWNER EXPERIENCING THIS ISSUE. THIS TRUCK WILL BE UNSAFE TO DRIVE IF THE RECALL WORK IS NOT DONE. PLEASE HELP. THANK YOU. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).*TR

NHTSA ID

10445100

Incident

Dec 14, 2011

Mileage

105,000 mi

ENGINE CHECK LIGHT ON DUE TO SMALL LEAK IN EVAPORATION CONTROL. TOYOTA DEALER INSPECTION DETERMINED LEAKING FILLER TUBE. COST TO REPLACE $350+. HOW MANY OF THESE COMPLAINTS ARE NECESSARY BEFORE THIS IS RECOGNIZED AS A DEFECT? *TR

NHTSA ID

10430173

Incident

Oct 1, 2009

Mileage

80,000 mi

CHECK ENGINE LIGHT CAME ON AND DEALER ADVISED THE FUEL FILLER TUBE HAD TO BE REPLACED FOR SEVERAL HUNDRED DOLLARS. THIS SEEMS TO HAPPEN IN MOST 2003 TUNDRA ACCORDING TO RESEARCH. BECAUSE TRUCK HAS 136,000 MILES, DEALER REFUSED TO PROVIDE ANY HELP WITH COST OF LABOR OR PARTS. DEALER DID ACKNOWLEDGE THIS HAS BEEN A PROBLEM FOR 2003 MODELS. SO MUCH FOR TOYOTA DEPENDABILITY. *TR

NHTSA ID

10390310

Incident

Feb 9, 2011

Mileage

136,000 mi

CHECK ENGINE LIGHT ALWAYS ON GIVING GAS CODES. AFTER EXTENSIVE RESEARCH THIS IS A COMMON PROBLEM WITH 2003 TOYOTA TUNDRAS. MINE HAS BEEN ON MY TRUCK FOR 3 YEARS SINCE I BOUGHT IT, AND I CONSTANTLY NEED TO GET IT RESET, UNTIL I DECIDE TO PAY TO GET IT FIXED. *TR

NHTSA ID

10384439

Incident

Dec 1, 2008

TL-THE CONTACT OWNS A 2003 TOYOTA TUNDRA. THE CONTACT BEGAN TO SMELL GASOLINE INSIDE THE VEHICLE. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHERE THEY WERE UNABLE TO DIAGNOSE THE FAILURE. THE FAILURE CONTINUED SO THE VEHICLE WAS TAKEN BACK TO THE AUTHORIZED DEALER WHERE A LEAK WAS FOUND ALONG THE WELDING WITHIN THE FUEL TANK. THE FUEL TANK WAS REPLACED. THE FAILURE MILEAGE WAS 52,754 AND THE CURRENT MILEAGE WAS 54,754. SM.

NHTSA ID

10378436

Incident

Oct 24, 2010

Mileage

52,754 mi

ENGINE CHECK LIGHT. DURING EMISSION INSPECTIONS IT WAS DETERMINED THAT A REPAIR WAS NECESSARY. CRACKED FUEL FILTER WAS REPLACED. TOTAL COST OF REPAIR $320. *TR

NHTSA ID

10355135

Incident

Aug 26, 2010

Mileage

26,000 mi

MY 2003 TOYOTA TUNDRA HAD A CHECK ENGINE LIGHT COME ON. DIAGNOSTIC CODES POINTED TO THE FUEL FILLER TUBE AND AIR PRESSURE TESTS BY MY PERSONAL MECHANIC (NOT A TOYOTA DEALERSHIP) PROVED THAT THERE WAS A CRACK IN THE FUEL FILLER LINE. THE MECHANIC STATES THAT THEY SEE THIS HAPPENING IN MANY TOYOTA'S THEY WORK ON. THEY SUGGESTED MENTIONING THIS TO TOYOTA DIRECTLY, SO WHEN I GO IN FOR MY OTHER RECALL (SEVERE CORROSION OF THE REAR CROSS-MEMBER) I AM GOING TO BRING THE ORIGINAL FUEL FILLER TUBE THAT I HAD TO REPLACE FOR $300. I ALSO SEE COMPLAINTS BEING FILED FROM OTHER TUNDRA OWNERS ABOUT THIS SAME ISSUE HAPPENING TO THEM. *TR

NHTSA ID

10340726

Incident

May 5, 2010

Mileage

59,000 mi

TL*THE CONTACT OWNS A 2003 TOYOTA TUNDRA. THE CONTACT NOTICED THAT THE MAIN FRAME OF THE VEHICLE WAS PERFORATED DUE TO SEVERE RUST CORROSION. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER FOR INSPECTION AND THEY REPLACED THE RUSTED FUEL TANK FILLER NECK. THE VEHICLE WAS TAKEN BACK TO THE DEALER ON A SEPARATE OCCASION. THE TECHNICIAN DETECTED A RUSTED BRAKE BACKING PLATE, AND THE FRONT AND REAR BRAKES WERE REPLACED. IN ADDITION, FOUR NEW TIRES WERE MOUNTED ON THE VEHICLE. THE TECHNICIAN WAS UNABLE TO PERFORM A TIRE ALIGNMENT DUE TO THE SIGNIFICANT FRAME DAMAGE. THE VIN WAS UNABLE TO BE ENTERED INTO THE SYSTEM. THE FAILURE MILEAGE WAS UNKNOWN AND THE CURRENT MILEAGE WAS 62,000.

NHTSA ID

10277979

Incident

May 18, 2007

THERE IS A FLAWED DESIGN OF THE FUEL FILLER NECK CAUSING THE CHECK ENGINE LIGHT TO COME ON. SERVICE ADVISOR STATED THAT IT WAS A KNOWN PROBLEM BUT BECAUSE MY WARRANTY WAS OUT, THEY WOULD NOT COVER THE REPAIR WHICH ENDED UP COSTING ME $462.32. MY MILEAGE IS ONLY 14,500. *TR

NHTSA ID

10212724

Incident

Dec 21, 2007

Mileage

14,495 mi

I TOOK MY 2003 TOYOTA TUNDRA IN TO TOYOTA MOTORS, GUAM BECAUSE I HAD A CHECK ENGINE LIGHT. TOYOTA THEN SENT A MESSAGE TO MY VEHICLE SERVICE CONTRACT, WARRANTECH AUTOMOTIVE INC AND THEY SAID THAT THE FUEL FILLER NECK HOSE ASSEMBLY WAS NOT COVERED. READING INFORMATION ON THE INTERNET INDICATES THAT THIS IS A COMMON PROBLEM WITH THE 2003 TOYOTA TUNDRA DUE TO A "OUT OF ROUND" GAS FILLER TUBE. THERE SHOULD BE A RECALL ON THIS PART. PLEASE ASSIST CONSUMERS LIKE MYSELF FOR TOYOTA MOTORS TO INVESTIGATE THIS DEFECT WITH THE 2003 TOYOTA TUNDRA. THE WORD NEEDS TO GET OUT. *NM

NHTSA ID

10166189

Incident

Aug 22, 2006

Mileage

35,000 mi

FUEL TANK FILLER WAS GIVING AS THE REASON OF MY TRUCKS PROBLEM BEFORE IT WAS LOOKED AT BY A TECHNICIAN. I WAS TOLD THAT THIS WAS A COMMON PROBLEM WITH THESE TRUCKS. THE FAULT WOULD CAUSE THE EMISSIONS SYSTEM TO FAIL AND THEREFORE WOULD ALSO BE A HAZARD BECAUSE IT COULD CAUSE A FIRE AT THE TIME THE TRUCK WAS BEING FILLED OR FROM ESCAPING VAPORS. THE PART WAS (IS) BEING REPLACED AND IS COSTLY TO THE CONSUMER. *NM

NHTSA ID

10155808

Incident

Apr 20, 2006

Mileage

42,500 mi

THERE IS A FLAWED DESIGN OF THE FUEL FILLER TUBE CAUSING AN INTERMITTENT CHECK ENGINE LIGHT. THIS IS A KNOWN PROBLEM THAT TOYOTA HAS WITH ITS 2003-2004 TUNDRAS. THE PROBLEM AFFECTS FUEL VAPOR EMISSIONS FROM THE GAS TANK. THEY OFFER NO SUPPORT ONCE ONE IS OUT OF WARRANTY EVEN THOUGH THEY ARE AWARE OF THEIR FAULTY DESIGN/BUILD OF THIS PART. *NM

NHTSA ID

10154747

Incident

Mar 31, 2006

Mileage

37,000 mi

WHILE DRIVING AT APPROXIMATELY 60 MPH VEHICLE CAUGHT ON FIRE. THE FIRE WAS DISCOVERED AFTER ABOUT 45 MINUTES OF DRIVING, AND IT WAS BETWEEN THE CAB AND THE BED OF THE VEHICLE. OWNER CONTACTED THE MANUFACTURER, AND WAS TOLD THAT THEY WOULD LOOK IN TO IT. *AK.....*AK

NHTSA ID

10115077

Incident

Mar 10, 2005

Mileage

34,168 mi

ENGINE LIGHT ON. I HAVE TAKEN IN 3 TIMES. UNKNOWN CAUSE/EMISSION SYSTEM OR FUEL SYSTEM. ENGINE HAS 2206 MILES ON IT. *LA

NHTSA ID

10041641

Incident

Sep 15, 2003

Mileage

2,206 mi