2005 Toyota Tundra Suspension Problems

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

Frame is rusted beyond repair both in the front and rear of the truck. fuel tank strap is rusted threw and fuel tank is hanging by one strap and not far from the ground.

NHTSA ID

11608286

Incident

Aug 12, 2024

THIS VEHICLE WAS RECALLED FOR FRAME RUST ISSUES. THE DEALER UNDER COATED THE FRAME IN-LIEU OF REPLACING IT, AS THEY HAVE DONE WITH SO MANY OTHERS. NOW I'M FACING A SAFETY ISSUE, AS THE FRAME HAS RUSTED THROUGH IN CRITICAL AREAS. THE MAJOR CONCERN IS IF THE FRAME SNAPS IN HALF WHILE UNDER HIGH SPEEDS CAUSING AN ACCIDENT AND POTENTIALLY INJURING OTHER AND OR MYSELF. I HAVE CONTACTED THE MANUFACTURER AND THEY PROVIDED A CASE NUMBER (240530000550). THE DEALER IS AWARE OF THIS ISSUE AND THEY WERE THE ONES THAT RECOMMENDED CONTACTING THIS ORGANIZATION AS WELL AS THE MANUFACTURER.

NHTSA ID

11591576

Incident

May 30, 2024

The contact owns a 2005 Toyota Tundra. The contact stated that while driving at 35 MPH, the driver’s side front ball joint detached causing the front driver’s side wheel to bend inward. No warning lights were illuminated. The vehicle was towed back to the residence which caused damage to the fender. The dealer was made aware of the failure and informed the contact that the vehicle was previously repaired under NHTSA Campaign Number: 07V013000 (Suspension) however, the failure occurred. The vehicle was not diagnosed or repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 290,000.

NHTSA ID

11584995

Incident

Apr 23, 2024

Mileage

290,000 mi

Frame rusted thru to point it is unsafe to drive

NHTSA ID

11572303

Incident

Jan 15, 2024

Frame corrosion through out the entire frame. Recently the steering rack broke away from the frame cross member. Now every time I turn the wheel there is a popping sounds and the steering feels loose compared to what it did before the sound accord. There is also a hole in the back of the frame behind the back tire. My attached tow package ripped sections of the frame and caused crack to extend towards the front of the frame. The fuel tank straps are also severely corroded.

NHTSA ID

11572033

Incident

Feb 15, 2024

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

NHTSA ID

11567142

Incident

Nov 13, 2023

Toyota did an inspection for frame rust years ago, but mine is now rusting out I believe it should have been swapped at the time of the recall.

NHTSA ID

11501973

Incident

Jan 13, 2023

It’s has come to my attention that this is an on going issue with tundra frames rusting out after being sprayed I inherited this truck from a family friend and the truck is getting to where it’s not drivable for frame issues this needs to be addressed by Toyota ASAP!!

NHTSA ID

11500816

Incident

Oct 5, 2022

******* 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

i recently purchased the 2005 Tundra I was instructed to take the Tundra to Westbury Toyota for inspection and they didnt even took at the truck they claimed according to the VIN is not eligible for any consideration from Toyota North North America The frame has recessive deterioration. We understand the truck doesnt have lifetime warranty but I am disappointed in Toyota's response

NHTSA ID

11492862

Incident

Nov 9, 2022

I own a 2005 Toyota Tundra 4dr. and in January of this year 2022 a recall was sent out on ‘Inadequate Hardness of Ball Joint Housing’. My Tundra is having ball joint problems meaning skeeking on the front wheels, vibrating until over 55 mph., and suspension problems. I called a Toyota dealership to get the truck fixed but they told me that back in 2007 the ball joints were already fixed. I shouldn’t be having this problem if the recall just came out. I’m trying to get this problem corrected on my truck without having to pay the $900 bill they want to charge me to fix it. Whst can I do ??

NHTSA ID

11482290

Incident

Aug 31, 2022

Front left wheel fell off. What component or system failed or malfunctioned, and is it available for inspection upon request? FRONT LEFT WHEEL. YES, AVAILABLE FOR INSPECTION How was your safety or the safety of others put at risk? WHEEL FELL OFF Has the problem been reproduced or confirmed by a dealer or independent service center? YES. TOWED TO SHOP; THEY AGREED THAT FRONT LEFT WHEEL FELL OFF. Has the vehicle or component been inspected by the manufacturer, police, insurance representatives or others? CAPITOL BODY SHOP, RIDGELAND, MS Were there any warning lamps, messages or other symptoms of the problem prior to the failure, and when did they first appear? UKNOWN. VEHICLE HAS MADE NOISE OFF AND ON, BUT WHETHER DUE TO THIS I CANNOT SAY. PLEASE NOTE: THIS VEHICLE WAS SUBJECT TO Recall Number 07V013000 Recall Date 01/19/2007 lOWER BALL JOINT. THIS VEHICLE HAD THAT SERVICE DONE IN LAS VEGAS NEVADA AT APPROX 12,500 MILES. WHAT FAILED WAS THE FIXED/REPAIRED/REPLACED JOINT. ALL

NHTSA ID

11461379

Incident

Apr 18, 2022

Mileage

225,000 mi

I believe my Toyota frame is rusted. The truck has 56,000 miles. The front wheel has a noticeable problem with the camber - it can not be driven safely.

NHTSA ID

11456625

Incident

Jul 25, 2019

the frame has rotted to the point the vehicle cannot be driven. rusted with holes all in it unsafe

NHTSA ID

11445453

Incident

Dec 15, 2021

I dont know exactly is the front ball joint or something else but something happen when run and stop the tundra, all the time hear a noise how to something is broke

NHTSA ID

11437867

Incident

Oct 23, 2020

The leaf springs have broken and frame is showing serious rust damage. Brake lines were leaking and had to be replaced.

NHTSA ID

11428481

Incident

Feb 17, 2021

Perforations in frame along seams due to rust isolated to the driver side front frame rail. Toyota is aware of this problem and refuse service and repair.

NHTSA ID

11419380

Incident

May 29, 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

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

LIMITED SERVICE CAMPAIGN DSD 2004-11006 TUNDRA FRAME INSPECTION. I BOUGHT AN 05 TUNDRA LAST YEAR. CALLED TOYOTA AND THEY SAID THIS RECALL IS OVER. MY FRAME NEEDS REPAIRING. THEY ARE NOT HELPING. DO I HAVE ANY RECOURSE?

NHTSA ID

11403240

Incident

Mar 16, 2021

WHILE DRIVING DOWN THE ROAD MY SPARE TIRE MOUNT FAILED DO TO RUST CORROSION CAUSING MY SPARE TIRE TO FALL OFF OF MY VEHICLE. UPON INSPECTION THE ENTIRE REAR FRAME AS WELL AS PARTS OF THE FRONT ARE CORRODED AND FLAKING CHUNKS OF METAL OFF. THIS RUSTING ALSO AFFECTS SUSPENSION MOUNTS AND THE ENTIRETY OF THE REAR AXLE.

NHTSA ID

11399878

Incident

Mar 8, 2021

Mileage

139,500 mi

CATASTROPHIC BALL JOINT FAILURE (DRIVER SIDE UPPER BALL JOINT) WHILE DRIVING AT SLOW SPEED.

NHTSA ID

11399055

Incident

Mar 3, 2021

Mileage

219,000 mi

TL* THE CONTACT OWNS A 2005 TOYOTA TUNDRA. THE CONTACT STATED WHILE DRIVING 40 MPH, THE DRIVER'S SIDE FRONT BALL JOINT BENT UNDERNEATH MAKING THE VEHICLE DIFFICULT TO STEER. THE VEHICLE WAS NOT TAKEN TO A LOCAL DEALER OR AN INDEPENDENT MECHANIC TO BE DIAGNOSED OR REPAIRED. THE CONTACT REPLACED THE PART HIMSELF. THE FAILURE RECURRED WITH THE FRONT PASSENGER'S SIDE BALL JOINT BEING BENT. THE MANUFACTURER HAD BEEN INFORMED OF THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 300,000.

NHTSA ID

11396960

Incident

Mar 8, 2020

Mileage

300,000 mi

SIGNIFICANT FRAME CORROSION IN MULTIPLE AREAS TO INCLUDE ONE AREA WITH A HOLE ALL THE WAY THROUGH THE FRAME RAIL, AND MOST ACUTELY WHERE THE REAR LEAF SPRING CONNECTS TO THE FRAME WITH ONLY 50% OF THE CONTACT AREA APPEARING TO BE STRUCTURALLY SOUND. DEALER STATES NOTHING THEY CAN DO. TWO AUTO RESTORATION SHOPS STATE THE FRAME IS GOING TO FAIL AND CAUSE AN ACCIDENT.

NHTSA ID

11373943

Incident

Nov 9, 2020

Mileage

225,000 mi