2008 Toyota Tundra Body & Structure Problems

The contact owns a 2008 Toyota Tundra. The contact stated that the rear subframe of the vehicle was extremely rusted. The vehicle was driven to an independent mechanic to be inspected, and it was determined that there was severe corrosion to the rear subframe. The vehicle was not repaired. The manufacturer was made aware of the failure, and the contact also informed the manufacturer that similar vehicles were under an undisclosed recall. The failure mileage was 284,023.

The 2016 Toyota Frame Rust Settlement (Burns v. Toyota Motor Sales, U.S.A., Inc.): This $3.4 billion class action directly addresses premature corrosion in 2007–2008 Tundras (and similar models). It claims Toyota “knowingly failed to apply adequate rust protection,” leading to frame perforation despite later treatments like HOF. The settlement’s “recurrent perforation” clause applies even after HOF. My rusted-through fuel tank strap and holes in the rear cross member qualify. HOF RO# XXX. Claim #XXX My 2008 Tundra SR5 TRD was treated with HOF in Nov 2017. In November 2025 my mechanic told me the gas tank was falling out as the straps that hold the tank in place were completely rotted out. And rust perforation was on the rear cross member. He instructed me to get a safety inspection at a Toyota dealership to document the rust. Toyota of Waldorf didn’t even schedule a appt, they told me to call the Brand Engagement Center and that there was no possibility of repair because Toyota had no frames. Brand engagement refused to provide any guidance. I scheduled an inspection at Koons Toyota of Annapolis, which it failed inspection with multiple >10mm frame holes and a rusted-through tank strap (held by bungee). They deemed it unsafe to operate and unrepairable. They kept leaving out the information about the rust or the holes until they realized I was not leaving until they documented it properly. I have 3 versions. Despite ZH7 expiration, this is a post-HOF recurrence and safety hazard. I requested goodwill repurchase at 1.5x KBB (~$12k) under the settlement’s intent. The Brand Engagement Center had me call them and [XXX] ” announced she was my case manager, then almost as quickly announced it was going to “Internal Dept” for repurchase review, that she would no longer be my case manager, and that they would get back to me in 60 days. I said the average is 2-4 weeks, not months and that I expected a response in 3-7 days. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Standard Vehicle Components failed. My 2008 Tundra [VIN [XXX] ] was inspected in Nov 2017 under HOF/WEP, passed with CRC applied, but now has a 2-finger-wide perforation in the frame and rusted through the gas tank support—a clear safety defect in a salt state like Maryland. The undercoating failed prematurely; I need goodwill frame replacement or buyback per the $3.4B settlement’s spirit.” (reference the 2017 class action, case no. 3:14-cv-03538). Toyota Brand Engagement Center has refused my request for repair or replacement or buy back. They also refused to provide written refusal. They admitted to recording the conversation, but refused my request for a copy or to record the call myself. There is literally no rust on any other portion of my truck as it is garage kept. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Years back there was a recall in regard to the frame. I brought the truck into Colonial Toyota in Milford CT for the recall. I was advised that the frame was fine and did not need to be replaced. Recently when i brought the truck in for an oil change the owner advised me that the gas straps attached to the frame had rusted out. He demanded that I remove the vehicle from his facility ASAP due to the excessive danger this created and not to drive the truck. He advised me to get rid of it. I reached out to a mechanic who advised that it could be welded back; however it would cost thousands of dollars to have that done. I contacted Toyota corporate to explain the situation and they advised me that there was nothing they could do to assist me with this issue. This truck had been well maintained and it ran perfectly with 280,000 miles. My goal was to run it to 400,000 miles as Toyota trucks tend to have a high mileage longevity when serviced as required. New A/C was replaced within the last three years; brakes/rotors/belts were replaced within the last 18 months. This truck was well maintained. Since this was my work truck I needed a vehicle ASAP and ended up purchasing a new 2024 Toyota Tundra which was an expense that I hadn't been expecting at all. I opted for the extended warranty option that was an EXTRA $3,000.00 to protect me and the new truck going forward. Toyota should be responsible for some of these additional expenses as it was TOYOTA who advised me during the RECALL that the frame was fine and DID NOT need to be replaced. Obviously that was not correct and they should be held responsible for the negative and very expensive outcome that this caused.

The floor inside of the bed is sagging everywhere it is bolted down to the frame. It has never had a bedliner. It has a crunchy sound when you step on these areas. I do not know how much damage is under the flooring at this time. There has been nothing heavy hauled in the bed. The rest of the bed is solid. If not repaired the bed will separate from the truck and soon

The entire outside of this truck is rusting. The frame is completely rusted as is the outside of the vehicle and the bed which you can see the ground when looking down. This is ridiculous. It looks like the area that hold the gas is also rusted and is dangerous to drive.

Frame rusting away, will no longer pass inspection because of cracks. First recall inspection dealer said it was OK second frame replacement is $10,700.00

The contact owns a 2008 Toyota Tundra. The contact stated that the subframe had severe rust-causing holes shown in the frame and cabbed of the vehicle. The contact stated that some areas had been sprayed with a substance to patch up the areas of rust, however, the spray had since deteriorated. The contact had not taken the vehicle to the dealer to be inspected. The contact informed the manufacturer of the failure and was informed that the extended coverage for the repair had been extended. The approximate failure mileage was 130,000.

The contact owns a 2008 Toyota Tundra. While driving approximately 45 mph, the fuel tank detached from the vehicle. The contact was able to tie the fuel tank to the vehicle with a rope until he was able to get to safety. The dealer was made aware of the failure and confirmed that the subframe needed to be replaced however, the repair was not covered under warranty. The vehicle was not repaired. The manufacturer was made aware of the failure and opened a case. The approximate failure mileage was 181,000. THE CONSUMER STATED BOTH FUEL TANK STRAPS CORRODED CAUSING THE FUEL TANK TO DROP.

Bed rust in areas where bed bolts to frame. Known issue by Toyota as evidenced by their TSB issued in 2012. Bed mat has been used since purchasing vehicle on 2010. Bed has rusted through at one location, rust is visible at another and the other two locations the paint is bubbling up. Contacted my local Toyota dealership (9/2020) and forwarded to the collision/repair shop manager. He supposedly sent an email to a district/area manager with pictures. I contacted him a couple weeks later and he said he hadn’t heard back and would sent it to another individual. I asked for the original email along with the new one. Original email was never furnished. Couple more weeks passed and I followed up yet again. Was told my vehicle was too old and nothing could be done. No official letter from Toyota, just a verbal statement. This rust will eventually cause a lack of support in the bolt area and may be an extreme safety issue while driving the truck and/or those driving beside or behind the vehicle if/when the bed disconnects from the frame. Incident date is the reported date to dealership. I am positive it had been ongoing under the bed mat quite prior to that date.

REAR LEFT FUEL TANK BRACKET BROKE OFF FROM TRUCK FRAME. IT APPEARS TO HAVE BROKEN AT WELD. SEE PHOTO. NOTICED PROBLEM WHILE DRIVING DUE TO BRACKET RUBBING AGAINST DRIVESHAFT AND SCRAPING ON ROAD. PREVIOUSLY, FUEL TANK BRACKET ON SAME VEHICLE SNAPPED AND HAD TO BE REPLACED. TRUCK TOWED TO SHOP FOR REPAIR. I WILL KEEP BROKEN PART ONCE REMOVED FROM TRUCK. *TR

I HAD MY TRUCK BED RHINO LINED WHEN NEW. I NOW HAVE ONLY 95,000 MILES ON IT AND THE BED IS RUSTING FROM UNDERNEATH. I LOWERED THE SPARE TIRE AND COULD SEE THE CORROSION MORE CLEARLY. THE RUST IS ACTUALLY BUBBLING UP THE RHINO LINER.TOYOTA DID ISSUE A RECALL FOR THIS ISSUE, HOWEVER MINE WAS NOT SHOWING THESE ISSUES AT THE TIME, NOW THE RECALL HAS EXPIRED. TOYOTA KNOWS THERE IS A PROBLEM, THEY NEED TO EXTEND THE RECALL SO THAT VEHICLES CAN BE REPAIRED SAFELY AND PUT BACK ON THE ROAD WITHOUT THE BED FALLING OFF. *TR

I HAD REACHED OUT TO TOYOTA REGARDING THE PREMATURE CHASSIS RUST ISSUE ON THEIR TRUCKS. I HAD INADVERTENTLY MISSED THE CUT OFF DATE FOR THE COATING WHICH WAS IN MAY OF 2018 DUE TO AN UNAVOIDABLE PERSONAL EVENT. WHAT DIDN'T MAKE SENSE WAS THAT THEY EXTENDED THE CAMPAIGN TO REPLACE THE CHASSIS IF THE PERFORATION WAS DEEMED SEVERE UNTIL JANUARY OF 2020. I HAD THE CHASSIS INSPECTED BY A TOYOTA DEALER BEFORE THIS JANUARY CUTOFF DATE. WHILE THERE ISN'T SUFFICIENT PERFORATION TO WARRANT A REPLACEMENT BUT IT IS CLEARLY EVIDENT THAT THE CHASSIS WAS NEVER PAINTED AND THE RUSTING ON THE CHASSIS IS CLEARLY PROMINENT FOR A VEHICLE OF THIS AGE. WHAT IS MOST DISCONCERTING IS THAT THEY WOULD EXTEND THE WARRANTY TO REPLACE THE FRAMES BUT THEY WOULD NOT EXTEND THE CUTOFF TO COAT THE CHASSIS. SHOULDN'T THIS COATING BE COVERED BY THE MANUFACTURER WITHOUT A CUTOFF DATE? MY TRUCK HAS BEEN VERY WELL TAKEN CARE OF, NEVER ABUSED AND ALWAYS WASHED AFTER SNOW STORMS BUT DUE TO NO FAULT OF MY OWN WHEREAS THE INITIAL CHASSIS COATING WAS FAULTY I AM NOW FACED WITH A TRUCK THAT LOOKS ALMOST MINT BUT THE CHASSIS WILL BE FAILING PREMATURELY. I HAD REACHED OUT TO TOYOTA BUT THEY FLAT OUT REFUSED TO PROVIDE THE COATING AS I MISSED THE CUTOFF DATE. I AM CONCERNED THAT THIS WILL SOON BECOME A SAFETY ISSUE AS THE TRUCK WILL LOSE IT'S STRUCTURAL INTEGRITY WITHOUT THE CRUCIAL COATING TO INHIBIT THE RUSTING. PLEASE LET ME KNOW IF THERE IS ANYTHING THE NHTSA CAN DO TO HELP, THANK YOU.

BOUGHT 2008 TUNDRA IN 2015. BODY EXCELLENT SHAPE. HAD 46000 MILES ON IT. BLOWED A BRAKE LINE AND PUT ON RACK TO MAKE REPAIRS THIS PAST MONTH. BRAKE LINES RUSTED AND FRAME IS ROTTEN. I CAN RUN MY FINGER THROUGH THE FRAME. I PAID 25.000.00 FOR THIS TRUCK. WAS TOWING A CAMPER WHEN BRAKE LINE BLEW. WAS HARDLY ABLE TO GET CAMPER HOME. WILL YOU FOLKS REPLACE THIS FRAME? OR WILL YOU STAND GOOD FOR IT. I STILL OWE ON IT. IT IS PARKED FOR THE TIME BEING AND NOT SAFE TO DRIVE.

I HAD LIFTED THE BED LINER ON MY TUNDRA AND FOUND THE BED TO BODY MOUNT AREA RUSTED THROUGH WITH HOLES IN IT. THERE IS A TECH BULLETIN FOR THE EXACT ITEM BUT I AM OUT OF WARRANTY. IT HAS A HOLE IN THE BED NOW. IF I HAD LIFTED IT YEARS BEFORE I FEEL THE RUST WOULD HAVE BEEN SEEN AND IT TAKEN CARE OF. TOYOTA WILL DO NOTHING FOR IT NOW. I HAVE NEVER HAD A TRUCK RUST THRU SO FAST.

MY TAILGATE LATCH BROKE ON ME AGAIN. THIS IS THE SECOND TIME THAT IT HAPPENED IN TWO YEARS. I WAS JUST GOING TO LET MY TAILGATE DOWN AND THE LATCH BROKE. THE VEHICLE WAS STATIONARY.

ALSO MY 08 TUNDRA JUST LIKE MY 03 TOYOTA SEQUOIA HAS THE PAINT COMING OFF THE HOOD AND VERY TOP OF TRUCK INCLUDING CHIPPING AND PAIN COMING OFF AND CLEAR COAT, HAS TO BE BAD PAINT THERE USING.

THE BED OF MY TRUCK IS RUSTING OUT IN THE AREA WHERE THE HOLD-DOWN BOLTS ARE. BEFORE LONG HALF OR MORE OF THE BOLTS WILL BE USELESS AND THE BED COULD COME OFF. NOTHING ELSE ON THE TRUCK BODY IS RUSTY AT ALL. THIS IS OBVIOUSLY A DEFECT AND IT NEGATIVELY EFFECTS THE SAFETY OF MY TRUCK. THIS HAS BEEN GOING ON FOR YEARS BUT I JUST RECENTLY BECAME AWARE OF THE FULL EXTENT OF THE PROBLEM.

SO LONG STORY SHORT MY 2008 DOUBLE CAB 6.5 FOOT BED WAS TAKEN BACK TO THE DEALER FOR THE FACTORY OR DEALER (IN MID 2009) INSTALLED PLASTIC BED LINER RUBBING THE PAINT OFF IN THE BED AND DISCOLORATION OF THE BACK BUMPER OR DELAMINATION AS TOYOTA CALLED IT. TOYOTA REPLACED THE BUMPER FREE OF CHARGE DUE TO THE CORROSION WARRANTY AND THE DEALERSHIP NOT UNDERCOATING THE BACK OF THE BUMPER, GREAT NO PROBLEM THERE. BUT NEVER IN ANY OF THE RECORDS DID THE SERVICE REP RECORD THAT THE BED COULD CORRODE! LATER TO FIND OUT WHEN TAKING THE TRUCK TO GET A SPRAY IN LINER I DROPPED IT OFF IN AUGUST OF 2016 LATER TO GET A CALL SAYING I SHOULD TAKE A LOOK AT MY BED BEFORE THEY DID ANY WORK TO FIND A HOLE ROTTEN THROUGH THE BED AN PAINT THAT WAS BUBBLED, CRACKED AND FLACKING OFF. I DID SOME RESEARCH ON LINE TO FIND A TSB FOR MY EXACT PROBLEM. ITS TSB-0101-12, I NEVER GOT WORD OF THIS TILL I DUG ONLINE TO FIND THIS! I TOOK THE TRUCK TO TOYOTA TO BE TOLD THEY COULD NOT HELP ME BECAUSE THERE WAS NO WARRANTY. SO I CONTACTED THE NORTH EAST REGIONAL CLAIMS MANAGER TO BE TOLD THAT SINCE THERE WAS NO RECORD OF THIS COMPLAINT DURING THE WARRANTEE PERIOD THEY COULD NOT ASSIST. WOULD ANYONE HAVE ANY ADVICE ON WHERE TO TURN I MIGHT TRADE THE TRUCK IN TO NOT HAVE TO REPLACE THE BED

EXTREM RUST UNDER TRUCK