Toyota Tundra 2002 — Reported problems

The dealership and Toyota Engagement Center refused to service the 2 recalls that was critical for the truck since October 2025. It was supposed to be including frame replacement and other parts but Toyota Engagement decided to active buy back option and took advantage of low offer to solve the matter which I don't accept.

Frame and crossmember is rusting. Has one hole on each side of the frame where the cross member is attached inside the frame.

Frame failed inspection for holes in frame. Had part of frame welded and got inspected.11/01/2022. Had been turned down by Toyota dealer previously. Now with less than 10,000 miles added, has another location where frame has rusted thru , making inspection passing impossible. And driving dangerous. Needs a new frame nd Toyota said no, according to the dealer. New Country Toyota, Saratoga NY. Can I sue Toyota? Is there statute of limitations on frame defects? What are my options. Thank you for your time and consideration. [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Toyota won’t cover the safety recalls on my truck

Excessive frame corrosion and corrosion holes involving even rear subframe

Frame needs replacement

The date it started happening was probably late March now into April to present day as the receptacle on the driver side doesn’t click always and comes undone while on the road and can not get the seatbelt to go back in and has not been assessed or replaced by my local Toyota Dealer and the issue is getting worse these are Stock parts

The headlights and high beams are dim . When the high beams are on other cars oncoming are not affected as they never flash their lights because my high beams seem as though they are just headlights. Also the fact that the high beams shine like headlights, there is no option for brighter lighting which makes it hard to see far ahead. I live in a rural location off of a narrow highway with down slopes with water at the bottom on both sides of the highway where large wildlife such as deer are plentiful . Insufficient high beam lighting imposes unsafe travel conditions since the headlights are dim and the high beams are how the headlights should be leaving no option for brighter visibility. I noticed the lighting being dim years ago but I thought it was just something to do with my trucks lighting until I began searching online again for a remedy and found many other owners of the same year make and model with exactly the same issue. Therefore in conclusion perhaps is a manufacturer defect. My truck is the most reliable vehicle I have ever owned, it still runs great, I keep it well maintained and I intend to keep using it for as long as we both shall live. I am [XXX] and obviously my truck is over 20 years old and runs great, it would be terribly upsetting if an accident were to occur due to insufficient exterior lighting. I cannot remember exactly what it was I had previously contacted NHTSA regarding my truck , though the exterior lighting is of greater concern now. I noticed the dimness of the exterior lighting since I have been living in this location a lot because there are no street lights along the freeway nor highway as opposed to where I lived prior. Thank you very much for giving me the opportunity to express my concerns as I appreciate your time and consideration in this matter. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Was told about the recall awhile ago and they said that my frame was ok. But now I have a perfectly good truck in good condition other than a rusted frame. Had some work done and mechanic said it is unsafe to drive due to rusted frame. They know of the defect and only replace a few and it looks like others are dealing with what I am.

The contact owns a 2002 Toyota Tundra. The contact, who is an independent mechanic, stated that the fuel tank had detached. The contact stated that the subframe was extremely rusted. There were no warning lights illuminated. The contact stated that the failure was related to NHTSA Campaign Number: 09V444000 (Structure). The contact called the local dealer, but the vehicle was not diagnosed or repaired. The manufacturer was not contacted. The failure mileage was approximately 190,000.

My original owner 2002 Toyota Tundra Truck was being backed up in reverse with a utility trailer attached up a very, very moderate incline on a driveway pushing the trailer onto a gravel pad ALONGSIDE (parallel) the driveway. As it started to spin gravel the truck was put into a 4 wheel Drive LOW RANGE. This is in keeping with the TOYOTA owners manual publication 0M34417U Part Number 01999-34417 Print date 02-0109-01. We followed the manual instruction on 4 WD operation. Within a few feet the truck stopped as if the wheels had hit a curb and there was no further movement no matter the accelerator pedal position and the engine speed was unchanged as if it was in a stall. All of a sudden there was a loud bang underneath the truck and the truck raced rearward 8-10 feet jackknifing the trailer into a tree and upending the truck and trailer. We contacted Toyota on the incident and they had a third party look at the truck for brake condition, floor mat placement and throttle freedom at the body shop & Toyota closed the complaint file. Toyota IGNORED the circumstances and description of the incident in closing the complaint. We have been a very long time TOYOTA truck family and have owned SIX Toyota 4 wheel drives plus a Lexus all-wheel drive. In doing our own evaluation and investigation we have found that the truck went into a 4-wheel drive "wind-up" or "bind" and found information related on it from ASE Certification sites. NO MENTION of this potential issue is provided in the owners manual! We found that the torque from this can be over 4,000 ft/lb. and possible magnified even more by low range. When this bind suddenly is released the movement can be violent as happened here. Why is this not talked about in the owner manual? Why does Toyota ignore this reality? Indeed, the Toyota Rep. Mr. Ronald Inton said "he never heard of anyone backing up in 4 Wheel Drive"! WHAT?? We have the vehicle, photos, Toyota denial all available for review,.

The contact owns a 2002 Toyota Tundra. The contact stated that the frame and the front bumper were severely rusted. The vehicle was not diagnosed or repaired by an independent mechanic or dealer. The manufacturer was notified of the failure and referred the contact to the NHTSA Hotline for assistance. The failure mileage was approximately 117,000.

The contact owns a 2002 Toyota Tundra. The contact stated that after taking the vehicle to be checked for corrosion to the subframe, the contact was advised that there was significant corrosion on the subframe and the supports underneath the truck bed. The contact was informed that the vehicle was unsafe to drive with any type of load in the truck bed. The vehicle was not repaired. The manufacturer was not informed of the failure. The failure mileage was approximately 180,000.

My frame have a big hole

I was doing maintenance on front and lifted splash guard for access to bolt. On top of the frame, near the firewall, was severe rust. It looks as if the frame could crack at any time. If this happened in highway speed or in traffic, severe risk of injuries. These are known to have issues in salt states (had recalls) and I thought I checked it pretty good before buying. I think this may be from the air conditioning drain system.

There are several issues with these seatbelts. They either lock before we can get them buckled or once we unbuckle them, they do not retract and hang out the door, thus draining the battery. They get twisted and stuck in the plastic guide toward the top of the door. The last time this happened, I could not get the seatbelt unstuck despite working on it for almost an hour. I ended up cutting the seatbelt to get it unstuck. Now it is EXTREMELY difficult to use. I need to get it replaced ASAP at my own expense. Very unsafe not to mention frustrating. Also, worth noting is this has been an ongoing problem for years.

The contact owns 2002 Toyota Tundra. The contact stated that upon taking the vehicle to an independent mechanic for an oil change and tire rotation, she was informed that the subframe was severely corroded, and the vehicle was unsafe to be driven. The dealer and the manufacturer were not notified of the failure. The vehicle was not repaired. The failure mileage was approximately 250,000.

The contact owns a 2002 Toyota Tundra. The contact stated that while the vehicle was in for routine maintenance, the mechanic discovered severe rusting and corrosion on the subframe of the vehicle. The vehicle was taken to the local dealer who determined that the vehicle was unsafe to drive due to the severe rusting of the subframe. The contact was informed that the subframe needed to be replaced. The vehicle was not yet repaired. The manufacturer was not yet notified of the failure. The failure mileage was 200,000.

The contact owns a 2002 Toyota Tundra. The contact stated that while driving at an undisclosed speed, the vehicle began to vibrate, prompting the contact to maintain low speeds. After a visual inspection, the contact observed that the front passenger wheels had a negative toe. No warning lights were illuminated. The vehicle was taken to the dealer, who determined that the lower ball joint had separated from the knuckle. The vehicle was not repaired. After investigating the failure, the contact related it to NHTSA Campaign Number: 05V225000 (Suspension), but the VIN was not included. The manufacturer was notified of the failure but provided no assistance. The failure mileage was 249,000.

Sudden maximum acceleration accompanied by brake failure, without warnings, occurred on my 2002 Toyota Tundra 4.7L V8 causing loss of control of the vehicle, which ended in a rollover crash, resulting in total loss of the vehicle and injury to me. While departing a 25 mph zone (sign read "END 25 SPEED LIMIT") on a relatively straight section of the road, I very gently accelerated from 20 mph to 30 mph. As soon as the vehicle reached 30 mph, sudden maximum acceleration occurred. Taking my foot off of the gas pedal, first I verified that the gas pedal was not stuck or blocked, but the gas pedal was in the fully up position. I then pressed the brake pedal very hard, but it was locked in the fully up position and the brakes would not engage. I then verified that nothing was blocking the brake pedal underneath it. At that point, around 3 to 4 seconds after the sudden acceleration began, I had entered the first turn of a 30 mph "S" turn at a high rate of speed, while acceleration continued at the vehicle's maximum acceleration rate beyond my control with the brakes not engaging. In order to avoid collision with a camper motor home and a small car following it, I went into the oncoming traffic lane at the second turn of the "S" turn. My truck fish tailed and struck a reflector marker on the left side of the road. To avoid going down a 50+ foot, nearly straight down drop on the left side of the road, I turned right. To avoid striking the motor home, I turned left, then right again to try to gain control. My truck rolled on its left side and landed upright on the right side of the road. It had been accelerating at its maximum acceleration rate with the brakes failing to engage and fish tailing the entire time. The problem appeared to be a catastrophic failure of the electronic throttle control and/or related electronic systems.

I purchased 4 new Michelin P245/70 R16 from Costco 12/5/2011with 31250 miles. I am a career auto mechanic for 39 years at an independent auto shop (retired, due to disability, 9/2011). I noticed sidewall cracking within about 2 years, but dismissed it because I have never heard/seen an air pressure loss due to sidewall cracking. The cracking worsened over the years, but the air pressure was even for all 4. Fast forward to 2020, I noticed my RF tire very low, looked for punctures, none found while submerged in water. November 2022 the RF tire was totally flat (parked). I found the sidewall had failed. This was a first for me in my experience. I certainly do not trust the remaining tires. I found a recall on the same brand/model but not my size. I have only 13350 miles on these tires. Tread is very good. I don't drive this truck often, but I maintain my vehicles well. Air pressure has been maintained at 40PSI, 4PSI under the max. pressure. In my opinion this is an obvious case of a defect in materials. I have not contacted Michelin yet.

My frame is to the point that it can not be repaired. It was coated by Toyota years ago as a safety recall but it is to the point now that my mechanic says it is to bad to repair. I have called Toyota and they say there have been frame issues that have been recalled but not with this year and model. only 135,000 miles on the truck

The contact owns a 2011 Dodge Durango. The contact stated that there was severe corrosion on the entire under carriage and subframe and struts. The contact received notification of NHTSA Campaign Number: 09V444000 (Structure) however, the part to do the recall repair was unavailable. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue. The failure mileage was unknown. Parts distribution disconnect.

The contact called on behalf of a friend who owns a 2002 Toyota Tundra. The contact stated in 2012 there was an unknown under coding and a plug was repaired on the vehicle. The driver experienced shaking and vibration from the rack and pinion steering while driving at approximately 35 MPH. The driver found power steering fluid leakage and there was a crack in the front passenger side of the engine frame. The contact was unaware of any failure warning lights. The contact stated the transmission functionality was great. The vehicle was not diagnosed or repaired. The manufacturer was not notified of the failure. The approximate failure mileage was 200,000

During inspection of my Tundra, I was told by the Toyota service technician that the frame integrity is compromised and could lead to a catastrophic incident. This is a common issue, Toyota settled a class action lawsuit in 2019, but it was restricted to just the 2007-8 model years of the Tundra. There was an earlier recall, but the resolution was not a fix, it was just a patch, leaving thousands of first generation Tundras on the road still with the potential to cause serious safety exposure. Toyota had a frame replacement program for a few years, so they are aware that it’s an issue, but have not resolved for many owners. They sued the frame manufacturer, Dana Corp I believe, further proof that they knew it’s a problem.

The contact owns a 2002 Toyota Tundra. The contact stated that he previously received notification of NHTSA Campaign Number: 09V444000 (Structure). The vehicle was taken to the local dealer and repaired under the recall. Recently, the contact was informed by an independent mechanic that cracks had formed on the rear suspension due to severe corrosion. The contact then took the vehicle to another dealer, Kelly Toyota of Hamburg (1 Industrial Dr, Hamburg, PA 19526), and was informed that the recall was a one-time free repair and the dealer offered no additional assistance. The manufacturer was notified of the failure and informed him that the recall was too old. The vehicle was not repaired. The failure mileage was 81,324.

The Toyota Tundra 2002 truck did NOT deploy driver's side and passenger's side airbags in a collision consisting of frontal and left-sided collision with immobile objects, with frontal/top profound impact from standing tree. The car was up to date on its inspections and maintenance. The breaks, though appropriately checked and tested, would take longer than normal to break the vehicle. The seatbelt, if pulled hard enough, would easily dislodge from buckle, coming undone. The driver of this vehicle collided as described above and due to the failure(s) of the safety mechanisms in place, resulted in the death of the driver. The driver was restrained with seatbelt, however dislodged from buckle upon impact and NO airbags deployed. The issue(s) have been confirmed by the police report, the county police documented. The vehicle has been inspected by police officers, and possibly others, including the employees of the towing company. There was NO indication thats the airbag deployment was either "off" if possible, and or indications of airbag defect. No messages or lights were indicated for the failure of the deployment of the airbags. No messages or lights were indicated for the defect and or failure of the seatbelt not remaining intact with force. The person in reference PASSED AWAY on impact at scene. The failures of the safety mechanisms put into place for this vehicle are absolutely unacceptable and beyond subpar.

It has a rust frame

The contact owns a 2002 Toyota Tundra. The contact stated that there were holes in the subframe of the vehicle. The local dealer was contacted and informed the contact that the subframe was not treated with rust inhibitor. The vehicle was not repaired. The manufacturer was notified of the failure and informed the contact that the dealer was not able to spray the rust inhibitor on the vehicle due to Iowa not being a cold state. The approximate failure mileage was 134,000.

The frame on the truck is rusted out with holes through it and the metal is rusted out along the entire frame. The truck vibrates when driving and when inspected by the dealer, Kari Toyota, they advised it is unsafe to drive as the frame could break entirely and cause an accident. Report is attached. Toyota was contacted on several occasions by Kari Toyota and myself in May and June of 2021. I had the vehicle in for repair of the frame rust issue on June 15, 2012 but clearly the work was not done properly as the rust issue continued until the vehicle is now undriveable. The vehicle has only 106,681 miles which is low for a typical Toyota vehicle. Toyota refuses to repair the vehicle even though I had followed up on my end by bringing it in for the recall repair. I requested a letter from Toyota explaining why they won't cover the repairs and they refused to send one.

Extensive frame rust determined by local mechanic. Said the truck is unsafe to drive.

I've owned this vehicle for 18 yrs. During that time Air Bags have been replaced on models above and below my year model. Every two or three years, I inquired at Dealerships when this series will be replaced. Always with the same answer, not required because not enough accident reports to warrant replacement. During that time I've only had one small finder bender not affecting the Air Bags to deploy. Curious why this year and model was never required to replace Air Bags?

I almost hit another vehicle while braking at a stop light. My front brakes gave out. Had new brakes and rotors installed 2 yrs ago and after this incident found that my brakes failed because Toyota refused to fix this problem they knew existed 1 gen Toyota tundra. They changed enlarged the front caliber and pads on 2 gen Toyota because they realized the brakes whe re w to small on the big v8 trucks. I drove aprox 25000 miles on brand new brakes. I should not have to pay for upgrading my front brakes due to a manufacturer defect, How can they get out of recalling these vehicles it is very dangerous and hope they accept responsibility for improper equipment installed on vehicles. I read that they did upgrade some vehicles that where still in warranty why not all?? Vehicles regardless of warranty.???

First the gas tank let loose and fell half way off. Result was a new gas tank installed. then part of the frame rusted from the cab. This resulted in having to have it welded. Have had several service repair lights come on that resulted in more fixes. Today just about does it. The spare tire fell to the road because rust ate through what was holding it up. I have all the papers that show the repairs and what it has cost me. I have not done anything yet about spare tire. I have had the truck since 2013 and it has less then 94k miles on it. It had 35 when I bought it and I knew nothing about the rust problem recall. I certainly believe I should have a new frame or some kind of compensation. Over the years I have talked to several dealers that got me no where. I guess this is my last shot.

The frame has rusted so badly that the spare tire fell off into the highway and nearly caused the vehicle behind to almost wreck.Upon arrival at home I looked at the frame and noticed that the u-bolts holding the rear differential are almost rusted off and will need to be replaced. The entire frame is rusted badly. I think something should be done!!! This vehicle has been taken care of and has seldom been off-road. I am a 72 year old man who does not abuse my vehicle. Thank you Jerry Wakeland

on June 9th at about 2pm while driving through my neighborhood, my upper an lower ball joints on my 2002 Toyota Tundra separated from my vehicle causing a catastrophic loss of control of truck and tore my hub with tire from vehicle ripping the brake fuel line and shoving entire components up under my Tundra while losing control with no brakes or steering capability. It also destroyed the drivers side front tire. Needless to say if I was say...going 55 to 60 miles per hour on highway...I would not be writing this. Had truck towed to Checkered Flag Toyota and they quoted me a price of over1300$ in repairs... they are fighting me on fixing my truck damages even though said damages were caused by the ball joint recall on the 2002 tundra...recall I D#05v

2002 Tundra was recalled for the rusty frame. I had mine inspected at the time of the recall. The dealership sprayed the frame of my truck. Now my frame is severely rusted and unsafe to drive. The balance of my vehicle is in good condition with approximately 200,000 miles. Will I be eligible for repair or replacement? Who should I contact? Thank you Bridgette Gartmann

My vehicle is unsafe to drive due to how badly the frame is rusted.

LOUD KNOCK TURNING THE WHEEL TO THE LEFT, RACK AND PINION LEAKAGE, INNER OUTER TIE RODS CAN SNAP CAUSE AN INJURY OR DEATH. HEADLIGHTS ARE VERY DIM EVEN THE BRIGHT LIGHTS ARE DIM. AN ONCOMING CAR IS NOT EVEN PHASED WHEN I HAVE MY BRIGHT LIGHTS ON. IT'S DIFFICULT TO SEE VERY WELL WITH THOSE [XXX] LIGHTS THEY'RE ALMOST IN AMBER COLOR TRIED TO USE LENS RENEW DID NOT WORK. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

RUST PROBLEM IN FRAME AND REAR CROSSMEMBER