2003 Toyota Tacoma Suspension Problems

While driving at both high speeds (highway) and local road speed limits, Toyota Tacoma's rear passenger side frame split completely in half. While performing maneuvers such as right turns, vehicle wobbled and I, driver, lost temporary control of vehicle. Upon further inspection, rear driver side frame also contains stress fractures which are symmetric to the rear passenger side of truck. Potential for accident has increased exponentially. Pictures provided. Brought evidence of clear safety hazard to local Metro Detroit dealership at 773 S Rochester Rd Unit B, Rochester Hills, MI 48307 on 04NOV25, and called Toyota Corporate on 05NOV25. Toyota Corporate neglected my concerns about safety hazard and potential harm to myself and family. Safety recall needs to be issued immediately. This issue stems from a well known recall from Toyota of Toyota Tacoma's, 1996-2004, which contained an OEM defect of excessive corrasion to the frames, causing premature failure of the frames due to excessive rust build up which impacts frame integrity and increases probability of failures such as observed in my case.

What component or system failed or malfunctioned, and is it available for inspection upon request? While driving over railroad tracks, the lower ball joint separated from its socket, which caused the CV axle shaft to break apart and led to the separation of the upper ball joint. As a result, the front driver's side tire folded under the fender, causing the truck to abruptly veer off the road and into the right shoulder All parts are available for inspection How was your safety or the safety of others put at risk? When the failure occurred, I was driving over a series of railroad tracks when the truck suddenly veered off the road onto the shoulder. This abrupt veering and stopping put my safety—and the safety of others—at risk, as the drivers behind me had to react suddenly to avoid a collision. Has the problem been reproduced or confirmed by a dealer or independent service center? The truck was serviced in 2006 in response to the recall, having the lower ball joints replaced, however the replacement parts may have failed Has the vehicle or component been inspected by the manufacturer, police, insurance representatives or others? No Were there any warning lamps, messages or other symptoms of the problem prior to the failure, and when did they first appear? No

The contact owns a 2003 Toyota Tacoma. The contact stated while driving at an undisclosed speed, the front driver’s side wheel detached from the vehicle. The contact was able to navigate the vehicle to safety. The vehicle was towed to an independent mechanic where it was diagnosed that the front driver’s side ball joint had failed and needed to be replaced. The contact was informed that the VIN was included in NHTSA Campaign Number: 05V225000 (Suspension). The vehicle was towed to the dealer where the vehicle remained and was diagnosed that the rear frame was rusted and needed to be replaced. The dealer informed the contact that the vehicle was included in an unknown warranty extension; however, the vehicle was not repaired. The manufacturer was notified of the failure, but no assistance was provided. The failure mileage was approximately 310,000.

The contact owns a 2003 Toyota Tacoma. The contact stated that the entire subframe of the vehicle was rusted due to severe corrosion. There were no warning lights illuminated. The vehicle was taken to an independent mechanic who confirmed the subframe corrosion. The vehicle was not repaired. The manufacturer was notified of the failure. The approximate failure mileage was 200,000. The VIN was not available. The contact stated that there was an opportunity to have the frame of the vehicle coated but that make the corrosion worse. The contact feels as though the vehicle is unsafe to drive.

THE FRAME IS ROTTED AND WAS NEVER ADDRESSED TO BE FIXED

I PURCHASED MY 2003 TACOMA SECOND HAND BACK IN 2015 WHICH SERVES AS MY PRIMARY VEHICLE TO THIS DAY. AFTER RETURNING FROM A YEAR LONG DEPLOYMENT OVERSEAS, I HAD A FEW FRIENDS OVER ON 4JUN OF WHICH ONE WAS ADMIRING MY TRUCK UNTIL HE LOOKS UNDERNEATH AND NOTICES ALL THE FRAME RUST. HE ADVISES THAT THERE IS A RECALL ON IT AND I SHOULD CONTACT MY TOYOTA DEALER TO GET IT SERVICED. FEELING DISTRAUGHT, I GO ONLINE AND LOOKUP RECALLS FOR MY CAR WHICH LED ME TO THE "FRAME RUST" SAFETY ISSUE ON A MANY TOYOTA MODELS TO INCLUDE MY OWN. THE ADVISEMENT SUGGESTS SAFETY CONCERNS WITH THE FRAME RUSTING THROUGH DUE TO FACTORY NEGLIGENCE IN SUFFICIENTLY COATING WITH ANTI-CORROSION MATERIALS. FURTHER RESEARCH IN OTHER FORUMS STATE OTHER TOYOTA OWNERS DESCRIBING IT AS FRAME RUST ALTOGETHER AND NOT JUST ON THE SPARE TIRE PLATE. ISSUES DESCRIBED INCLUDE THE ISSUE CAUSING THE LEAF SPRING TO SNAP AND THE FRAME ITSELF RUSTING THROUGH. INSPECTION OF MY TRUCK PROVES TRUE TO ALL ACCOUNTS DESCRIBED. I CONTACTED SERVCO TOYOTA IN HONOLULU, HI THE VERY NEXT DAY AND SPOKE TO A NICE LADY. I EXPLAINED HOW I BECAME THE OWNER OF THE VEHICLE SINCE 2015 AND WAS NEVER MADE AWARE OF THIS RECALL. SHE CHECKED MY VIN TO CONFIRM THAT I WAS AFFECTED BY IT, HOWEVER THE RECALL HAS EXPIRED AS OF 2018 SO THERE IS NOTHING THEY CAN DO. SHE GAVE ME THE 1-800 NUMBER TO TOYOTA WHICH LED ME NOWHERE AND KEPT DIVERTING ME BACK TO SERVCO TOYOTA INSTEAD OF THEIR MAIN OFFICE..... WHAT FRUSTRATES ME THE MOST IS THAT TOYOTA PROVIDED ME NO NOTICE OR WARNING ABOUT THIS RECALL. SO HOW CAN I REACT TO SOMETHING I WAS NEVER MADE AWARE OF. SAFETY RECALLS SHOULD NEVER HAVE EXPIRATION DATES AS IT REMAINS A SAFETY ISSUE UNTIL ITS PROPERLY REMEDIED. *TR

TL* THE CONTACT OWNS A 2003 TOYOTA TACOMA. THE CONTACT STATED THE CHECK ENGINE WARNING LIGHT WAS ILLUMINATED. THE VEHICLE WAS TAKEN TO INDEPENDENT MECHANIC, WHERE SHE WAS INFORMED THAT THE DRIVER?S AND PASSENGER?S SIDE REAR SUBFRAME AND REAR LEAF SPRING WERE FRACTURED AND NEEDED TO BE REPLACED. THE VEHICLE WAS TAKEN TO BERLIN CITY TOYOTA OF PORTLAND LOCATED AT 191 RIVERSIDE ST, PORTLAND, ME 04103 (207) 618-6528, AND THE DEALER WAS MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT DIAGNOSED NOR REPAIRED. THE MANUFACTURER WAS INFORMED OF THE FAILURE. THE FAILURE MILEAGE WAS 160,000.*DT 8/14/2020 EDIT BY [XXX]: I WOULD ALSO LIKE TO ADD THAT THE TACOMA WAS BROUGHT INTO THE SEASHORE TACOMA DEALERSHIP IN NEW JERSEY BACK IN 2013 FOR A DIFFERENT RECALL AND THE FRAME RECALL WAS NEVER ADDRESSED OR BROUGHT UP TO ME WHILE MY TACOMA WAS THERE. I WOULD ALSO LIKE TO NOTE THAT IN 2016 WHILE I WAS STATIONED IN ALASKA, I RECEIVED A POST CARD ABOUT THE EXTENDED WARRANTY. I PROMPTLY CALLED THE NUMBER AND WAS ADVISED THAT THE WARRANTY DID NOT PERTAIN TO MY TACOMA. OTHERWISE, I WOULD HAVE PUT IT ON THE FERRY TO JUNEAU FOR THE INSPECTION. LASTLY, I HAVE OWNED THIS TACOMA SINCE 2009. IT AS BEEN STATIONED WITH ME FOR 4 YORK IN FL, 4 YORK IN NJ, 4 YORK IN SITES, AK AND 2 YEARS IN ME. IT ALSO PREVIOUSLY LIVED BETWEEN IN KY AND FL PRIOR TO ME. HAD I BEEN ASKED THE RIGHT QUESTIONS ABOUT THE ORIGIN OF THE TACOMA THEN I'M SURE THEY WOULD HAVE TOLD ME THE TRUCK WAS ELIGIBLE FOR THE EXTENDED WARRANTY. *DT INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).'*JB

FRAME IS RUSTING.

BOUGHT THE TRUCK USED, FRAME RUSTED, FROM COLD WEATHER STATE, HEARD LOTS OF TRUCKS DID THIS, RUST SO BAD AFRAID TO DRIVE IT,EVERYTHING ELSE ON TRUCK GOOD, FROM WHAT I UNDERSTAND IT'S HAD 5 RECALLS, NOT ONE DONE BY FORMER OWNER, INTERNET WEB SITE SAID FRAMES WERE NOT COATED RIGHT, FACTORY DEFECT, WANT TOYOTA TO FIX ISSUE AS IT'S THEIR FAULT THIS HAS HAPPENED, IT'S DANGEROUS TO DRIVE.

BROUGHT TRUCK INTO BODY SHOP IN JUNE 2019 TO HAVE WORK DONE. THEY TOLD ME THE FRAME ON THE TRUCK WAS SEVERELY RUSTED IN SEVERAL PLACES. THEY SAID IT MAY BE UNSAFE TO DRIVE. IN 2016 (ABOUT 2.5 YRS AGO) I BROUGHT THE TRUCK INTO THE LOCAL TOYOTA DEALER TO HAVE FRAME INSPECTED UNDER A RECALL NOTICE. AT THAT TIME THEY TOLD ME THAT THE FRAME WAS OK. IN ADDITION THE TRUCK WAS AT THE DEALER IN 2018 FOR ANOTHER RECALL FOR LEAF SPRINGS. AT THIS TIME THEY REPLACED LEAF SPRINGS BUT DID NOT REPORT ANY PROBLEMS WITH FRAME RUST. THE ORIGINAL BODY SHOP AND MY LOCAL CAR REPAIR SHOP TOLD ME THAT THE SEVERITY OF THE RUST DAMAGE ON THE TRUCK INDICATED THAT THIS HAS BEEN GOING ON A LONG TIME AND WERE SURPRISED THAT IT HAD PASSED TOYOTA DEALER FRAME INSPECTION. I CALLED TOYOTA NATIONAL LINE AND THEY TOLD ME THAT FOR FRAME REPLACEMENTS FOR MY TRUCK THE PROGRAM ENDED IN JANUARY 31 2019. SUBSEQUENTLY I TRIED TO WORK WITH THE LOCAL DEALER AND THEY HAVE ALSO TOLD ME THAT NATIONAL TOYOTA WILL NOT HELP. CLEARLY THE SEVERITY OF THE PROBLEM (SEE ATTACHED PHOTOS) INDICATES THAT THE RUST DAMAGE WAS HAPPENING OVER A LONG PERIOD OF TIME AND TOYOTA WAS NEGLIGENT IN REPORTING THIS TO ME. TOYOTA SHOULD TAKE RESPONSIBILITY FOR REPAIRING/REPLACING THE FRAME SINCE CLEARLY THE PROBLEM HAS EXISTED LONG BEFORE THE JANUARY 31 2019 DATE AND I HAVE FOLLOWED UP ON ALL THE RECALL NOTICES FOR THIS TRUCK.

TL* THE CONTACT OWNS A 2003 TOYOTA TACOMA. WHILE DRIVING 35-40 MPH, THE FRONT SUSPENSION EXPLODED. THE FRONT PASSENGER SIDE TIRE FLEW UNDERNEATH THE VEHICLE AND THE BRAKE LINE SNAPPED. THE VEHICLE MOVED ONTO THE SIDE OF THE ROAD. THE DEALER AND MANUFACTURER WERE NOT CONTACTED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 172,661.

TL* THE CONTACT OWNS A 2003 TOYOTA TACOMA. THE CONTACT STATED THAT THE REAR FRAME WAS RUSTED AND THE PASSENGER SIDE WHEEL BEARING DETACHED. THE HUB FOR THE WHEEL BEARING WAS LOOSE AND DETERIORATED. THE CONTACT STATED THAT THE VEHICLE CONTINUED TO RUST AND WAS TAKEN TO AN INDEPENDENT MECHANIC WHO REFUSED TO SERVICE THE VEHICLE BECAUSE THEY DID NOT HAVE THE CORRECT CERTIFIED PARTS. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS CONTACTED AND DID NOT ASSIST. THE FAILURE MILEAGE WAS 107,000.

FRAME IS ROTTEN AND BROKEN, SHOCKS RIPPED OFF OF FRAME. UNSAFE TO DRIVE AND STILL NEED TO USE DAILY.

TL* THE CONTACT OWNS A 2003 TOYOTA TACOMA. WHILE THE VEHICLE WAS COASTING INTO A FUEL STATION, THE FRONT PASSENGER SIDE BALL JOINT DETACHED FROM THE TIRE INDEPENDENTLY AND WITHOUT AN IMPACT. THE VEHICLE WAS TOWED TO THE CONTACT'S RESIDENCE AND LATER TOWED TO TOYOTA OF WHITTIER (LOCATED AT 14577 E, WHITTIER BLVD, WHITTIER, CA 90605, (562) 222-5386). THE DEALER DIAGNOSED THAT THE BALL JOINT BECAME LOOSE AND NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE AND INFORMED THE CONTACT THAT THE VEHICLE WAS REPAIRED PER NHTSA CAMPAIGN NUMBER: 05V225000 (SUSPENSION) IN 2005. THE MANUFACTURER PROVIDED CASE NUMBER: 1902250627. THE CONTACT STATED THAT THE RECALL REPAIR FAILED. THE APPROXIMATE FAILURE MILEAGE WAS 230,000.

TL* THE CONTACT OWNS A 2003 TOYOTA TACOMA. WHILE DRIVING VARIOUS SPEEDS, A POPPING NOISE WAS PRESENT FROM THE REAR OF THE VEHICLE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO DISCOVERED THAT THE REAR DRIVER'S SIDE SPRING HANGER WAS RUSTED AND DETACHED FROM THE VEHICLE. THE CAUSE OF THE FAILURE WAS NOT DETERMINED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE LOCAL DEALER WAS NOT CONTACTED. THE FAILURE MILEAGE WAS 146,000 *BF.. CONSUMER STATED WHILE SEARCHING THAT TOYOTA WAS AWARE THAT THE FRAME WAS SUSCEPTABLE TO CORRISION AND THERE WAS A RECALL/ REEPLACEMENT PROGRAM BUT HAS EXPIRED.*JB

THE REAR BRAKE LINES THAT CONNECT OVER THE REAR AXLE RUSTED INTO AND CAUSED THE BRAKE FLUID TO LEAK FROM THE BRAKING SYSTEM. WHEN THE TRUCK WAS TAKEN INTO A LOCAL SERVICE CENTER FOR REPAIR TO THE BRAKES THE SERVICE CENTER REPRESENTATIVE INFORMED ME THAT THEY COULD NOT REPAIR THE BRAKE LINES BECAUSE THE FRAME WAS RUSTED SO SEVERELY THAT IF PUT ON A LIFT THE FRAME WOULD FALL APART AND THE TRUCK WOULD BREAK IN HALF. THE SERVICE CENTER DETERMINED ALSO THE TRUCK WAS NOT SAFE TO DRIVE. SERVICE RECORDS AT THE DEALERSHIP ARE ON FILE WHERE THE TRUCK WAS TAKEN TO THE DEALERSHIP FOR INSPECTION OF THE FRAME AND REPORTED THE TRUCK DID NOT HAVE A RUST ISSUE AS DESCRIBED IN THE LETTERS I RECEIVED AND HEEDED THE WARNING TO HAVE THE TRUCK INSPECTED.

TL* THE CONTACT OWNS A 2003 TOYOTA TACOMA. THE CONTACT STATED THAT THE VEHICLE WAS RECENTLY SERVICED BY A MECHANIC WHO INDICATED THAT THE VEHICLE WOULD NOT PASS INSPECTION DUE TO EXTENSIVE RUST AND CORROSION OF THE FRAME. THE VEHICLE WAS NOT INCLUDED IN ANY RECALLS FOR THE FRAME. THE DEALER WAS NOT CONTACTED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS NOT AVAILABLE. *TT CONSUMER CONTACTED THE DEALER ON 12/17/18 REPRESENTATIVE STATED NOTIFCATION WAS MAILED W/O A RESPONSE. CONSUMER STATED NO NOTIFICATION WAS SENT, REPRESENTATIVE STATED SHE WOULD GET BACK TO THE CONSUMER ON 12/18/18 BUT NEVER DID.*JB

WHILE TRAVELING AT ABOUT 40 MPH, RIGHT FRONT PASSENGER WHEEL SUDDENLY AND UNEXPECTEDLY BROKE OFF AT THE BALL JOINTS. THE TIRE FOLDED UNDER THE CHASSIS AND THE TRUCK SKIDDED TO A STOP IN THE ROAD SHOULDER.

WE BOUGHT OUR 2003 TACOMA BRAND NEW FROM THE DEALER IN 2003, EXPECTING THIS TO BE A 30-YEAR INVESTMENT. WE HAVE KEPT UP ALL MAINTENANCE ON THIS TRUCK WITH OUR MECHANIC. HE CHECKED IT LAST YEAR AND FOUND NO ISSUES WITH THE FRAME OTHER THAN SOME NORMAL RUST. LAST WEEK WE TOOK IT TO HIM BECAUSE THE CHECK ENGINE INDICATOR WAS ON, AND HE DISCOVERED THAT OUR FRAME WAS COMPLETELY RUSTED THROUGH WITH HOLES IN THE DRIVER'S SIDE. HE DEEMED IT COMPLETELY UNSAFE TO DRIVE AND RECOMMENDED THAT IT BE TOWED TO THE DEALER BECAUSE THE FRAME WAS NEAR THE POINT OF BREAKING IN HALF. WE NEVER RECEIVED ANY NOTICES FROM TOYOTA. WE PERFORMED ALL RECALLS THEY ISSUED. AFTER AN ONLINE SEARCH, WE DISCOVERED THE EXTENT OF THIS FRAME ROT PROBLEM OVER MANY TOYOTA TRUCKS. WHEN WE CALLED TOYOTA CORPORATE, THEY DISMISSED US AND TOLD US THAT WE WERE OUT OF LUCK RECEIVING ANY HELP OR COMPENSATION FOR THIS DEFECT BECAUSE WE HAD MISSED DEADLINES ON A CLASS ACTION SUIT AND ALSO THAT THERE WAS AN EXTENDED WARRANTY ISSUED ONLY FOR SOME TACOMAS IN CERTAIN COLD WEATHER STATES. WE WERE NEVER NOTIFIED OF ANY OF THIS INFORMATION AND HAVE LIVED AT THIS SAME ADDRESS WITH THE SAME CONTACT INFORMATION SINCE THE TIME OF PURCHASE. WE WENT TO THE DEALERSHIP WHERE WE PURCHASED IT AND THEY ALSO COMPLETELY DISMISSED US, TELLING US THAT IT WAS OUT OF THEIR HANDS AND WE COULD TRY TO CONTACT CORPORATE TO JOIN ALL THE OTHER TRUCK OWNERS WITH THIS FRAME ROT PROBLEM AND TRY TO SEE IF THEY MIGHT HELP US. THIS TRUCK HAS ONLY 37,479 MILES. AS MUCH AS I'M DEVASTATED THAT WE ARE NOW OUT MANY THOUSANDS OF DOLLARS BECAUSE OF TOYOTA'S UNSCRUPULOUS POLICIES, I'M MORE ANGRY THAT THEY KNOWINGLY HAVE PUT MILLIONS OF LIVES IN JEOPARDY BY COVERING UP THIS DANGEROUS PROBLEM. HOW MANY MORE VEHICLES ARE CURRENTLY ON THE ROADS EVERY DAY WITH THE RISK OF RIPPING IN HALF AND KILLING INNOCENT PEOPLE? THIS PROBLEM MUST BE FIXED PLEASE!

FRAME CORROSION, TOOK TACOMA IN FOR INSPECTION WHILE STILL UNDER WARRANTY, FRAME FAILED INSPECTION BUT TOYOTA DENIED CLAIM DUE TO OUTSIDE INFLUENCES.