2009 Toyota Tacoma Body & Structure Problems

The contact owns a 2009 Toyota Tacoma. The contact stated that after maintenance service on the vehicle, it was discovered that the front subframe of the vehicle was severely corroded. The vehicle was taken to an independent mechanic, where it was inspected, and determined that the entire subframe had failed and needed to be replaced. The vehicle was not repaired. The vehicle was then taken to the dealer, where the same diagnostic result was provide,d and the contact was informed that the entire subframe needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure. The approximate failure mileage was 85,000.

The contact owns a 2009 Toyota Tacoma. The contact stated that while driving at an undisclosed speed, there was an abnormal sound coming from underneath the vehicle. Upon inspection, the contact discovered a branch lodged beneath the vehicle and the corroded subframe with a hole in the front passenger’s side subframe. The vehicle was not diagnosed or repaired by an independent mechanic or dealer. The manufacturer was made aware of the failure. The failure mileage was approximately 113,000.

The contact owns a 2009 Toyota Tacoma. The contact stated that upon further inspection, the contact became aware that the chassis was rusted. The local dealer was contacted; however, the contact was informed that an unknown Toyota recall for warranty coverage had expired. The manufacturer was made aware of the failure. The failure mileage was approximately 110,000.

I just learned from my Mechanic that the Frame Corrosion is bad. The frame was inspected by Vanderstyne (now West Herr) Toyota on 06/20/2020. It passed the Inspection at that time, so they did not do anything. But within 4.5 years and only a little more than 6,000 miles driving since then - this corrosion shows up. I think the Toyota Specs for the Corrosion Inspection were not sufficient. Toyota should be held accountable for their negligence. I only have 72,900 miles on this Tacoma. I would have liked to keep it for another 5 years or so, but now I cannot and Toyota washed their hand when I contacted them.

See Attached Letter

THE FRAME HAS RUSTED AND HOLES ARE UNSAFE. I AM WORRIED ABOUT DRIVING MY VEHICLE. THE SAFETY OF ME AND OTHER DRIVERS ON THE ROAD I AM TRAVELING ARE AT RISK. I WENT TO LIBERTY TOYOTA IN BURLINGTON, NJ AND THEY REFUSED TO REPAIR. THE RUST IS UNUSUAL AND THERE HAVE BEEN OTHER YEARS AFFECTED AND FRAMES REPLACED. MY WIFE PURCHASED THIS TRUCK FROM LIBERTY TOYOTA

My frame is rusting and has holes in places. Is there a recall for that?

Chassis in the middle frame back left too much rust and big hole due to rust

Vehicle: 2009 Toyota Tacoma VIN: [XXX] Mileage: 128,400 Owner: Jacob Grove, Anderson, SC Summary of Issue: The frame of this 2009 Toyota Tacoma has developed severe rust perforation that makes the vehicle unsafe to drive. My independent mechanic has refused to work on it due to safety concerns, and Toyota of Greenville (SC) has confirmed that the frame is extensively corroded and requires replacement. Background: Toyota previously issued a Customer Support Program (CSP) for frame corrosion affecting 2005–2009 Tacomas in northern states, including Ohio, where this truck was purchased and operated. In June 2018, the vehicle was inspected at Don Wood Toyota in Athens, OH (91,600 miles). The dealership recorded “no perforation” and did not apply the protective coating or replace the frame. The truck has been minimally driven since (an average of 6,000 miles per year). In May 2024, at 128,400 miles, a mechanic and dealership confirmed the frame has multiple areas of severe perforation, including around brake lines and exhaust mounts. Concern: It is unreasonable that a vehicle frame could go from “no perforation” to “severe perforation” in only 36,000 miles and six years of light use. This indicates either: The 2018 inspection under Toyota’s CSP was inadequate, or The frame was already compromised but not properly addressed at the time. Safety Risk: The vehicle cannot be safely lifted, worked on, or driven in its current condition. The rapid deterioration presents a risk of frame failure while driving, endangering occupants and others on the road. Request: I am submitting this complaint so that NHTSA is aware of ongoing frame corrosion failures in 2005–2009 Toyota Tacomas, even in cases where Toyota previously inspected and declined to repair during the CSP period. This case demonstrates that the problem may not have been properly identified or corrected during program inspections, leaving unsafe vehicles on the road. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

We recently went to have new tires put on the Tacoma at Costco. The Costco technician said that the frame was rusted and he had a similar problem with his Tacoma and Toyota repaired it. He told us that he couldn't install the new tires with the rusted frame and suggested that we go to our Toyota Dealer. We went to Toyota Direct in Columbus, Ohio (where we have had the vehicle serviced every time) and they took pictures of the rust and told us they would call us back. Although we have inquired several times, they had not called us back so we reached out to Toyota Corporate and they said that the recall/warranty extension had expired and there was nothing they could do. Costco has refused to install the new tires until the frame is repaired. (our problem is not with Costco.) The Costco tech did tell us that he was surprised that the rust had not been noticed before by the Dealer during regular service as it would not have appeared so quickly. So the complaint goes against Toyota Corporate and Toyota Direct... why did they not notice any rust while the warranty/recall was in effect or any of the service visits if this is a standard problem with 2009 Toyotas. If the vehicle has a rusted frame, that could be dangerous to whoever is driving the vehicle. In addition, without being able to have new tires installed due to the frame issue, that creates another safety concern with winter weather approaching and tires that need replaced.

Just learned from CT Toyota dealer that my 2009 Toyota Tacoma frame has significant corrosion and that it's time to replace frame or vehicle. Very disappointed. Vehicle did go in for recall service on 12/7/17 and CRC spray was applied as frame was determined ok at that time. Looks like that didn't help much to prevent further corrosion less than 6 years later. Voicing my frustration over those that got new frames are still driving on road, while I have to retire my truck. Extending warranty to 12 years from date of first use clearly did me no help. Do I and others like this have any options?

Rust flaking frame small hole

I purchased this vehicle on 12/16/2019 with 20,990 miles on it. Now the vehicle has 33,000 miles on it and I was told by an independent service station that I have a large hole in the frame. I brought the truck on 4/07/2023 to a Toyota dealer and they said the recall for a new frame expired 12 years after the vehicle was purchased. I called Toyota and they told me the same thing. I had know idea that these trucks had frame rust issues when I bought it. I read that Canada received a 3 year extension to 15 years on Tacoma 2009 trucks with mileage under 36,000, I have only 33,000 miles. Please help!

The contact owns a 2009 Toyota Tacoma. The contact stated that he noticed that the subframe was excessively rusted. The vehicle was taken to a local dealer for routine oil change and tire rotation services, and after the contact made the mechanic aware of the failure, he was informed that the vehicle could not be raised up on the lift because the subframe had excessive rust and would fracture. The contact was informed that the subframe needed to be replaced. The contact then made Toyota of Bedford (18151 Rockside Rd, Bedford, OH 44146) aware of the failure; however, the dealer declined to diagnose or repair the vehicle. The vehicle was not repaired. The manufacturer was made aware of the failure. The approximate failure mileage was 104,000.

Went to get an undercoat application. Tech pointed out severe rust/rot on my truck frame, located on both front wheel control arm area. Vehicle was inspected by N.E. Undercoating, Plainfield Ct. No warnings. NEVER RECEIVED A FRAME RECALL NOTICE Contacted Toyota Corporation and they said "sorry, nothing we can do"

See attached document for complaint

The contact owns a 2009 Toyota Tacoma. The contact stated while driving at an unknown speed, the vehicle started shaking abnormally. The vehicle was taken to the dealer to be diagnosed. The contact was informed that the subframe needed to be replaced. The contact stated that she had received a recall in the past for the subframe however, the vehicle was not repaired. The dealer and manufacturer were notified of the failure but informed the contact that the recall had expired. The vehicle was not repaired. The failure mileage was approximately 95,000.

Never received notice for XX Warranty Enhancement Program and found out in March 2022 as vehicle cannot pass inspection due to rusty on frame. BRAND ENGAGEMENT ADVOCATE March 09, 2022 at 12:18 PM Dear [XXX], Thank you for contacting Toyota Motor Sales, U.S.A., Inc. regarding your frame concern in your 2009 Tacoma. We are sorry to learn you're experiencing a concern with your vehicle. We were able to further look into your frame concern and have verified your vehicle is beyond the parameters of the Warranty Enhancement Program for this concern. This warranty enhancement program was an extension of the vehicle's Basic Warranty. Primary coverage for this program expired on 01/31/19 and Secondary coverage for your vehicle expired 12 years after the date of first use: 06/30/20. Once the vehicle is outside of the program parameters, the cost of repairs becomes the owner’s responsibility, as the component is now outside of all factory coverage. We have also verified that one letter was sent to you at the mailing address we have on file. The remedy letter for the XX Warranty Enhancement Program was sent on 11/08/2018. We hope this provides clarity to your inquiry. Your comment has been documented at our National Headquarters under your case number. If we can be of further assistance, please feel free to contact us. Sincerely, [XXX] Toyota Brand Engagement Center INFORMATION Redacted PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).

Severe rusting and corrosion of chassis/under body, body and frame of truck.

The contact owns a 2009 Toyota Tacoma. The contact stated that while the vehicle was at an independent mechanic for routine maintenance, the mechanic informed him that there was a hole in the sub-frame and that the sub-frame was severely corroded. The vehicle was not repaired. The manufacturer was made aware of the failure but informed the contact that there was no recall associated with the VIN. Additionally, the extended warranty had expired. The vehicle had previously been serviced in 2017 when the dealer applied an undercoating to the subframe. The failure mileage was 65,136.