2005 Toyota Tundra Body & structure Problems

The frame is so rusted in my truck my mechanic said it may snap at anytime and is not safe to drive. I know Toyota tundra’s from 2000-2003 have been recalled for same reason.

NHTSA ID

11704087

Incident

Dec 9, 2025

This report addresses the critical structural integrity concerns related to excessive corrosion, and frame material loss affecting the main ladder frame chassis. The degradation of the frame members poses a significant and immediate safety risk, including potential catastrophic structural failure, detachment of critical components, and failure of safety systems (e.g., braking and fuel lines) mounted to the frame. Location: Mid-frame section (beneath the cab) and rear sections (near the leaf spring mounts and rear axle).

NHTSA ID

11696453

Incident

Oct 20, 2025

1)Frame is rusting out. Not repairable. 2) Fuel tank strap rusted through and broken.

NHTSA ID

11666631

Incident

Jun 12, 2025

know issue with Toyota Tundra Frame, and refuse to give option to repair.

NHTSA ID

11610237

Incident

Aug 22, 2024

We are the first owner of this 2005 Toyota Tundra Limited with only 91K miles. The frame is rusted so badly that we are afraid to drive down the road. This rusted problem could cause potential harm or death to us and others on the road.

NHTSA ID

11597528

Incident

Jun 28, 2024

The contact owns a 2005 Toyota Tundra. The contact stated that the sub frame was rusted and had holes. The parking brake and oil warning lights were illuminated. The vehicle was taken to the local dealer, who determined that the vehicle might not pass a safety inspection due to the position of the holes and rust. The warning lights were repaired but the sub frame was not repaired. The vehicle was taken to a frame shop, the frame shop declined to service the vehicle. The manufacturer was contacted and informed the contact about an Extended Warranty, but no assistance was provided. The failure mileage was approximately 139,000.

NHTSA ID

11593990

Incident

Jan 1, 2024

Mileage

139,000 mi

Frame rusted thru to point it is unsafe to drive

NHTSA ID

11572303

Incident

Jan 15, 2024

Frame and suspension is rotted away badly was recall on frame In 2005

NHTSA ID

11567142

Incident

Nov 13, 2023

Severe frame rust due to cheap frame material. Earlier year models were recalled but 05 and 06 were not, just a limited campaign. Frame looks like it has been coated before, but this is a known issue with these trucks. I have contacted Toyota and they basically said, sorry, we can't do anything.

NHTSA ID

11555176

Incident

Nov 1, 2023

Severe rust throughout the frame

NHTSA ID

11550454

Incident

Oct 15, 2023

Original owner. Well known frame rust safety issue as documented by thousands of 2005 Tundra owners. Toyota did an inspection for frame rust several years ago and opted for coating to deal with issue hastily given the long delay/backlog with replacing entire frame. Two wrongs don’t make a right. Now major safety/inspection issues with frame area and gas tank. Unable to allow my child to drive back to college. Not safe. Not worth risking kids lives. Would be interested to learn how many owner/operators need to report serious injury/fatalities before NHTSA enforces action against Toyota for corporate greed.

NHTSA ID

11540777

Incident

Aug 1, 2023

The driver's side front frame has rotted out disconnecting the mount for the anti-roll bar. This has happened despite several reports to the dealership going back many years that the frame was rusting rapidly which, upon examination, they said that it was OK. They did apply a coating which might have delayed the process a bit but ultimately resolved nothing. For trucks that had perforated frames during the first few years, they replaced the frame. I tried to take care of mine, but it has finally failed and they say the replacement program is over. They are unwilling to provide even the necessary frame section and mounting bracket for the sway bar (~$545) for the frame shop to install %(2120).This vehicle has less than 98,000 miles on it and is used for short trips performing farmette duties. Frame failure can cause catastrophic accidents and should not be ignored by the manufacturer regardless of age. They know they used bad steel and should act accordingly. My action has been delayed by storm damage to frame shop which didn't reopen until December.

NHTSA ID

11498671

Incident

Aug 30, 2022

The contact owns a 2005 Toyota Tundra. The contact stated while performing a routine inspection, the contact noticed that the subframe was rusted on the front and the rear suspension of the vehicle. The vehicle was taken to the dealer and the mechanic stated that the vehicle had a spray-on coating however, the vehicle was rusted and the subframe needed to be replaced. The vehicle was not replaced. The manufacturer was not contacted. The failure mileage was 60,000.

NHTSA ID

11498365

Incident

Dec 19, 2022

Mileage

60,000 mi

******* DELETE VOQ ******* THIS COMPLAINT IS BEING MARKED FOR DELETION BECAUSE THE CONSUMER PLACED THE REQUEST.*DJR ******* DELETE VOQ *******

NHTSA ID

11493011

Incident

Nov 10, 2022

The contact owns a 2005 Toyota Tundra. The contact stated that he was informed at the State Inspection facility that the entire sub-frame of the vehicle was severely corroded. The dealer was not notified of the failure. The manufacturer was notified of the failure and advised the contact that they could not assist as the vehicle was not included in a recall related to the failure. The vehicle was not diagnosed or repaired. The failure mileage was approximately 148,518.

NHTSA ID

11448270

Incident

Jan 20, 2022

Mileage

148,518 mi

The contact owns a 2005 Toyota Tundra. The contact stated that he was made aware of the vehicle's frame corrosion by an independent mechanic. The dealer was made aware of the failure but informed the contact that there was no recall associated with the VIN. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 98,000.

NHTSA ID

11445483

Incident

Dec 27, 2021

Mileage

98,000 mi

This vehicle was purchased as a certified used vehicle from Johnston Toyota. It was recalled by Toyota for a rust problem. In October 2014 the vehicle was treated by the dealer (Johnston Toyota) with a rust inhibiting compound due to the rust problem. Approximately 1-2 years ago this vehicle was inspected by an independent mechanic who stated that the vehicle was badly rusted, and he believed that Toyota had a program to address this issue. I spoke to the Toyota service department and I was told that this vehicle is not covered. Approximately 2 weeks ago an independent mechanic advised the rust problem is extensive and the vehicle will be unsafe to operate. Although Toyota advises that this is a widespread problem for this type vehicle, they refuse to address it. Furthermore, when I asked them why the rust inhibiting compound they used to correct the problem did not solve the issue, they further refuse to respond.

NHTSA ID

11437439

Incident

Oct 1, 2021

The contact owns a 2005 Toyota Tundra. The contact stated that while the vehicle was in for the state inspection, it was discovered that the subframe had sustained severe rusting and corrosion causing the vehicle to fail the state inspection. The cause of the rusting and corrosion was not determined. The local dealer and manufacturer were notified of the failure. The contact indicated that the vehicle was previously treated with a rust inhibitor coating, but the failure still occurred. The failure mileage was 311,000.

NHTSA ID

11433998

Incident

Sep 11, 2021

Mileage

311,000 mi

Frame is rusted. Whole on front passenger side frame.

NHTSA ID

11426572

Incident

Jul 12, 2021

FRAME IS VERY RUSTY. STRAP HOLDING FUEL TANK IS DANGEROUS , REAR SUSPENTION ,AND SHOCKS BROKEN

NHTSA ID

11426059

Incident

Jul 22, 2021

I seen that Toyota were recalled for the frame issues on 2004 and up, mine is 2005 tundra with frame issues, like it’s sad, such a nice truck, but frame is horrible. Why is mine not being shown as recalled, but yet I have frame problems? I got my truck from a 1 owner who had it since new, it just hit 100,000 miles on it, it was serviced by Toyota dealership, I’m not sure why they didn’t do nothing with it over the years to help or fix the rust issue on the frame. It’s not just a little rusty, it’s really rusty, and it was garage kept too. Did they forget to include my vin number when they started the recalls? Doesn’t make sense why they would fix some and not all, all around the same years. Thanks Jim

NHTSA ID

11420939

Incident

Jun 7, 2021

The frame has several holes in it. Toyota said they did the corrosion prevension on it and said the repair is out of warranty. The sway bar has broken free of the frame and there are several hole and flaking spots on the frame.

NHTSA ID

11417915

Incident

May 6, 2021

DISCOVERED SEVERE RUST THROUGH ON THE UNDERSIDE FRAME.

NHTSA ID

11413421

Incident

Apr 21, 2021

I PURCHASED A 2005 TOYOTA TUNDRA UNAWARE OF THE WIDE-SPREAD RUST ISSUES THIS MODEL FROM TOYOTA IS SUFFERING. THE VEHICLE CAME WITH AN INSPECTION STICKER FROM THE DEALER SO IT WAS WELL PAST THE DEALER'S WARRANTY WINDOW TO DO ANYTHING ABOUT THIS ONCE I FOUND OUT ABOUT THE ISSUE. THE VEHICLE WAS PURCHASED IN MAINE AND WAS SOLD TO ME IN NEW YORK. I WAS INFORMED BY MY MECHANIC THAT THERE ARE 4 SERIOUS RUST ISSUES PRESENT ON THE VEHICLE THAT PREVENT IT FROM PASSING INSPECTION. 1) A LARGE SEVERAL SQUARE INCH PERFORATION IN THE CENTER OF THE FRAME MEMBER 2) "PANCAKING" PRESENT ON A LARGE SECTION OF THE FRAME 3) A LARGE PERFORATION IN ONE OF THE FRAME'S CROSS MEMBERS 4) A SIGNIFICANTLY RUSTED BODY MOUNT SOMEHOW, ONLY MODEL YEARS 2000-2003 WERE RECALLED FOR THE TUNDRA BY TOYOTA, AS IF THE REST OF THE GEN 1 TUNDRAS DIDN'T HAVE THE EXACT SAME FRAME PART NUMBER. WORSE YET, I REGISTERED ON TOYOTA.COM AND FOUND THAT THE PREVIOUS OWNER REQUESTED A FRAME REPLACEMENT 60,000 MILES AGO IN 2014. TOYOTA DID NOTHING AND INSTEAD APPLIED A "CRC" OR CORROSION RESISTANT COMPOUND TO THE TRUCK. BASED ON WHAT I'VE READ ONLINE THE APPLICATION OF THIS COATING THIS CAN MAKE YOUR TRUCK INELIGIBLE FOR THE RECALL SERVICE THIS ISSUE EFFECTIVELY TOTALS THE TRUCK AS IT WON'T PASS A SAFETY INSPECTION WITHOUT RECTIFYING THIS ISSUE. I AM IN QUITE AN UNFORTUNATE SITUATION AS A RESULT AS THIS IS MY ONLY VEHICLE.

NHTSA ID

11406801

Incident

Apr 6, 2021

Mileage

160,000 mi

2005 TUNDRA FRAME IS RUSTED IN MANY PLACES. VERY BAD WHERE FRAME SECTIONS MEET AND NOW THE FRAME IS RUSTING THROUGH THE MAIN HORIZONAL FRAME ITSELF AS THE ATTACHED PICTURE INDICATES. THIS HAS BEEN AN ONGOING ISSUE FOR YEARS BUT IS BAD ENOUGH NOW THAT IT IS NOT SAFE AND WILL NOT PASS INSPECTION. I KNOW THERE WAS A RECALL ON THIS FRAME AND I WAS TOLD IT WAS OK WHEN I BROUGHT IT IN FOR THE RECALL. I T HAS BEEN RUSTING EVER SENSE. WE HAVE ONLY PURCHASED TOYOTAS AND LEXUS VEHICLES FOR THE LAST 20 OR MORE YEARS AND THIS IS THE THIRD TRUCK RUST HAS TOTALED. PLEASE HELP

NHTSA ID

11406794

Incident

Jan 6, 2021