2004 Toyota Tacoma Suspension Problems

I was turning into a gas station and all the sudden the vehicle came to a complete stop i was unable to move the vehicle and sat there until the tow truck was able to show up. Looked under the vehicle and on the passenger side front suspension the lower ball joint was no longer where it belongs.

The vehicle has an open recall (NHTSA Recall #12V542) for the spare tire carrier lift plate. I brought the vehicle to a Toyota dealership to have the recall addressed, but the dealership refused to perform the repair, stating that the frame is too rusted to proceed safely. They recommended a full frame replacement due to severe rust damage, which includes holes and significant structural weakening. Toyota has refused to provide a replacement frame under any existing recall or warranty program. This means the recall cannot be completed, and the vehicle remains unsafe to drive. Additionally, I cannot locate a replacement frame for this vehicle through Toyota or the aftermarket, leaving no practical solution to address the safety risks. The refusal to honor the recall and the lack of available replacement parts put me and others at significant risk. The problem has been confirmed by the Toyota dealership during inspection, and the rust damage makes the vehicle structurally unsound. The unresolved recall, combined with the excessive frame rust, has created a double safety hazard that needs urgent resolution

2011- check engine light was illuminated. Toyota dealership attempted repairs 11 times but could not find a cause. They replaced 7 different sensors, replaced gas cap, charcoal filter.. still could not get light to go off. refused to continue servicing same issue with no fault. Since 2011, I have had to run diagnostics on a regular basis to ensure there are no other mechanical issues. 2022- gas tank fell off of truck while driving. The straps snapped off due to rust and tank fell to the ground. This issue could have caused GREAT bodily injury or DEATH. 2023-lost brakes while driving. TOTAL brake failure. local mechanic stated it was a proportioning valve failure. The housing for it was rusted through and cannot be removed safely. After multiple days of research, a replacement could not be located. Even contacting Toyota, part is unavailable so vehicle CANNOT be fixed. Total brake failure could have led to GREAT bodily injury or DEATH. ONGOING-- vehicle frame is extremely rusted. bumper has fallen off, spare tire fell off, brush guard rusted and fell off. The frame under cab near bed of truck is rusted through. gas tank straps rusted through and tank fell off. You can literally push fingers/hand through the flaking metal. ALL previous recalls were completed including undercoating but the rust has gotten so bad the vehicle is not safe to drive.

Lower ball joint detached, nearly caused major problems for me on the road

This vehicles frame has rusted and broken. I feel lucky to have made it home just as the frame cracked wide open on one side making the truck un-drivable. Had this happened on the freeway or somewhere out in a rural setting I may have been killed, caused a problem for other drivers or been stranded away from any help. I have sent a photo of the damage to a frame shop but an independent inspection is not, in my opinion, needed since the rusted, broken member is clearly visible to any lay person. There were no warning lights or anything associated with this problem. What I did feel was some serious shaking and bumping as I moved down the road toward my house.

The contact owns a 2004 Toyota Tacoma. The contact stated while driving 70 MPH and making a right turn, the front passenger’s side tire and wheel inadvertently detached from the vehicle. The contact was able to veer to the side of the road, where he noticed that the lower control arm had detached from the subframe and was resting on the floor. The vehicle was towed to the contact's residence. The dealer was notified of the failure and advised the contact that the vehicle could not be repaired under the NHTSA Campaign Number: 05V225000 (Suspension) because the VIN was not included in the recall. The manufacturer was not notified of the failure. The vehicle was not diagnosed nor repaired. The approximate failure mileage was 250,000.

TL* THE CONTACT OWNS A 2004 TOYOTA TACOMA. THE CONTACT STATED THAT HE INITIALLY NOTICED THAT THE REAR BUMPER WAS CORRODED. THE CONTACT BOUGHT A REPLACEMENT BUMPER AND TOOK THE PART TO AN INDEPENDENT MECHANIC TO HAVE THE BUMPER REPLACED. UPON INSPECTING THE VEHICLE, THE MECHANIC DISCOVERED SEVERE CORROSION AROUND THE FRONT PART OF THE LEAF SPRINGS ON THE DRIVER'S AND PASSENGER'S SIDE OF THE VEHICLE. THE CONTACT SPOKE WITH MIKE ERDMAN TOYOTA (4650 FL-520, COCOA, FL 32926) WHERE HE WAS INFORMED THAT THE VEHICLE WAS OUT OF WARRANTY AND ANY REPAIRS WOULD BE PERFORMED OUT OF POCKET. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS APPROXIMATELY 136,000.

TL* THE CONTACT OWNS A 2004 TOYOTA TACOMA. THE CONTACT STATED WHILE DRIVING 45 MPH, THE VEHICLE STARTED PULLING TO THE RIGHT. THE CONTACT STATED NO WARNING LIGHT WAS ILLUMINATED. THE CONTACT STATED THAT THE REAR SUBFRAME WAS RUSTED. RILEY TOYOTA LOCATED AT 2105 CHRISTY DR, JEFFERSON CITY, MO 65101, (573) 893-3100, WAS MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT DIAGNOSED NOR REPAIRED. THE MANUFACTURER HAD NOT BEEN INFORMED OF FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 175,124.

WHEN CHANGING THE OIL IN THE VEHICLE FOR THE FIRST TIME, IT WAS UP ON A LIFT AND IT WAS OBVIOUS THAT THE TRUCK FRAME WAS RUSTING THROUGH. THE BAD PART IS WHEN THE VEHICLE WAS PURCHASED LAST YEAR TOYOTA CHARGED US A $200 FOR CHECKING THE VEHICLE OUT, BUT EVEN THOUGH THERE ARE TONS OF COMPLAINTS DIDN'T BOTHER TO TELL US THAT THE FRAME WAS RUSTED. I HAVEN'T REPORTED IT TO THEM YET I WONDER IF THEY WILL STAND BEHIND THEIR INSPECTION. SO MUCH FOR GETTING A VEHICLE CHECKED OUT BEFORE YOU BUY.

TL* THE CONTACT OWNS A 2004 TOYOTA TACOMA. THE CONTACT STATED THAT THE SUSPENSION SPRING HANGERS WERE SEVERELY CORRODED. THE CONTACT STATED THAT THE SUBFRAME WAS ALSO CORRODED. THE MANUFACTURER OFFERED A WARRANTY WHICH WAS EXCEEDED. THE CONTACT STATED THAT THE VEHICLE WAS TAKEN TO KOONS TYSON TOYOTA LOCATED AT (8610 LEESBURG PIKE, VIENNA, VA 22182 (703) 790-5920) TWICE BY THE PREVIOUS OWNER AND RUST INHIBITOR WAS APPLIED TO THE SUBFRAME OF THE VEHICLE. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE AND CONFIRMED THAT THE WARRANTY PERIOD WAS EXCEEDED. NO ADDITIONAL ASSISTANCE WAS PROVIDED. THE APPROXIMATE FAILURE MILEAGE WAS 122,000.

TL* THE CONTACT OWNS A 2004 TOYOTA TACOMA. THE CONTACT STATED WHILE DRIVING 35 -40 MPH, THE PASSENGER'S SIDE BALL JOINT FAILED CAUSING DAMAGE TO THE SIDEWALL OF THE TIRE. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC TO BE DIAGNOSED. THE CONTACT WAS INFORMED THAT THE LOWER CONTROL LOWER BALL JOINTS, CONTROL ARM, BALL JOINT AND THE INNER AND OUTER TIE ROD NEEDED TO BE REPLACED. THE CONTACT STATED THAT THE STRUT ASSEMBLY, UPPER BALL JOINT, ABS SENSOR, AND PASSENGER'S SIDE BRAKE HOSE WERE REPLACED. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS CONTACTED AND INFORMED THE CONTACT THAT THE VEHICLE WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 05V225000 (SUSPENSION). THE FAILURE MILEAGE WAS 156,201.

TL* THE CONTACT OWNS A 2004 TOYOTA TACOMA. THE CONTACT STATED THAT UPON INSPECTION OF THE VEHICLE, IT WAS DISCOVERED THAT THE UNDERCARRIAGE SHOWED EXTENSIVE CORROSION TO THE SUB FRAME OF THE VEHICLE. THE VEHICLE WAS TAKEN TO TWO INDEPENDENT MECHANICS WHO INFORMED THE CONTACT THAT THEY WERE UNABLE TO FIX THE SUB FRAME OF THE VEHICLE. THE MANUFACTURER WAS CONTACTED AND THE CONTACT WAS INFORMED THAT THE PRIOR OWNER DECLINED TO HAVE THE CORROSION REPAIRED ON THE VEHICLE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 141,000.

2004 TOYOTA TACOMA FRAME RUSTED THROUGH, HOLE YOU CAN PUT HAND THROUGH. TOYOTA NEVER ISSUED RECALL, CLAIMS CORROSION CAMPAIGN WAS OVER. I NEVER RECEIVED ANY NOTICE, I AM THE ORIGINAL OWNER. TOYOTA SAYS I AM ON MY OWN FOR REPLACEMENT. FOUND ISSUE AT MY BROTHER'S HAD TO LEAVE TRUCK UNSAFE TO DRIVE. WILL ADD PHOTOS AFTER I GET BACK TO VEHICLE.

RIGHT BALL JOINT BROKE. WHEEL TUCKED UNDER VEHICLE. BROKE CV AXLE

BALL JOINT SEPARATED AND WHEEL TUCKED UNDER CAR. ALSO BROKE CV SHAFT

2004 TOYOTA TACOMA, TOOK TRUCK IN TO BE PAINTED WAS INFORMED THAT THERE ARE MULTIPLE BASEBALL SIZE HOLES IN THE FRAME AND THE LEAF SPRING MOUNTS ARE RUSTED AND LEAF SPRINGS ARE ABOUT TO POP OFF. I HAVE CALLED TOYOTA CORP, AND WAS TOLD BECAUSE TRUCK WAS NOT SPRAYED THEY WILL NOT HONOR THE FRAME. I RECENTLY ACQUIRED THIS VEHICLE AND WAS NOT AWARE OF THE RECALL THAT HAD BEEN ISSUED ON THIS TRUCK. TOYOTA AT THIS POINT IS REFUSING TO REPLACE OR REPAIR THE FRAME EVEN THOUGH THIS TRUCK ORIGINATED AND REMAINED IN A COLD CLIMATE STATE FOR MOST OF ITS EXISTENCE. PLEASE ADVISE IF THERE ARE ANY OPTIONS AVAILABLE TO HAVE TOYOTA HONOR THIS VEHICLE. THANK YO U

TOOK TRUCK IN FOR INSPECTION AND THE FRAME IS DETERIORATING TO THE POINT THE BED IS BECOMING DETACHED FROM THE FRAME AND SEPARATING FROM THE CAB. THE SUSPENSION IS COMING LOOSE FROM THE MOUNTS. THIS IS NOT THE ONLY ONE THE MECHANIC HAS SEEN WITH DETERIORATION. THESE TRUCKS ARE NOT SAFE TO DRIVE!!

I RECENTLY PURCHASED THIS 2004 TOYOTA TACOMA AND TOOK IT IN FOR AN INSPECTION OF THE FRAME FOR UNDERCOATING. THE BODY SHOP NOTED SEVERE CORROSION OF THE FRAME WITH SUSPENSION PARTS THAT ARE ALSO FULL OF CORROSION. I WAS TOLD THIS VEHICLE WAS NOT SAFE TO DRIVE DUE TO THIS RUST ISSUE. I WAS TOLD IF THIS VEHICLE WAS INVOLVED IN AN ACCIDENT THERE WOULD BE SERIOUS INJURY OR DEATH BECAUSE OF THIS RUST/CORROSION. I NEED THE MANUFACTURER TO TAKE CARE OF THIS FOR SOME REASON THIS VEHICLE'S FRAME WAS NOT RECALLED BUT THE BODY SHOP STATED THIS SHOULD HAVE HAD A SAFETY RECALL ON THIS FRAME DUE TO THE AMOUNT OF RUST THAT IS NOTED UNDER THE VEHICLE ON THE FRAME AND SUSPENSION PARTS.

The contact owns a 2004 Toyota Tacoma. The contact stated that while driving approximately 55 MPH, the passenger’s side axle fractured and the wheel detached. There were no warning lights illuminated. The vehicle was towed to an independent mechanic who replaced the ball joints. The local dealer was not contacted. On another occasion, while driving at an undisclosed speed, the driver’s side axle fractured and the wheel detached. The vehicle was towed to an independent mechanic who replaced the ball joints however, the failure recurred. The contact stated that the failure was related to NHTSA Campaign Number: 05V225000 (Suspension). The manufacturer was contacted but provided no assistance. The approximate failure mileage was 190,000.

SEPTEMBER 29, 2018 I WAS DRIVING ON THE INTERSTATE MY TACOMA'S FRONT END WOULD FEEL LIKE IT WOULD FLOAT OFF THE GROUND OR LIFT UP OFF THE INTERSTATE. I MADE IT BACK TO THE TOWN I LIVE IN AND STOPPED AT A GAS STATION FOR SOME GAS. AS I LEFT, TO GO PICK UP MY FIANC AND OUR 2 GIRLS TO GET BACK ON THE INTERSTATE AND DRIVE BACK WITH THEM TO WHERE I JUST WAS. I GOT ABOUT 3 BLOCKS FROM THE GAS STATION AS I WAS GOING 30 MPH. ALL OF A SUDDEN MY RIGHT FRONT END GOES DOWN AS IF A TIRE BLEW. WHEN I CAME TO A STOP AND WENT TO LOOK WHAT HAPPEN. I FOUND THAT I DON'T HAVE A FLAT TIRE BUT THAT MY RIGHT FRONT TIRE IS LYING ON ITS SIDE UNDER THE REAR OF THE RIGHT FRONT FENDER. THE UPPER AND LOWER BALL JOINT EACH SNAPPED IN HALF WHICH CAUSED MY TIRE TO BREAK LOOSE AND CAUSED ME TO SKID DOWN THE ROAD. THE RIGHT FRONT AXLE SHAFT, OUTER TIE ROD, STABILIZER BAR LINKS, SPINDLE KNUCKLE WERE ALL DESTROYED AND HAD TO BE REPLACED. SO WHEN I WAS ON THE INTERSTATE HEADING HOME TO GET MY FAMILY AND KEPT FEELING LIKE THE FRONT OF MY TRUCK WOULD RANDOMLY FLOAT UP WAS MORE THAN LIKELY BECAUSE MY LOWER BALL JOINT WAS ALREADY BROKEN APART. WHICH DRIVING ON THE INTERSTATE PUT ENOUGH STRESS ON THE UPPER BALL JOINT. THAT CAUSED THE UPPER BALL JOINT TO BREAK WHEN IT DID. TO THINK IF IT THE TIRE STAYED ON TILL I PICKED UP MY FAMILY AND GOT BACK ON THE INTERSTATE WITH MY 3 GIRLS AND THAT TIRE BROKE OFF.